Brake Pedal Support ASSY: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Inspect brake pedal height.
  Pedal height from asphalt sheet:
  
  144.1 - 154.1 mm (5.673 - 6.067 in.)
2. Adjust brake pedal height.
  1. Remove the instrument panel finish panel sub-assy lower and instrument panel insert sub-assy lower LH.
  2. Disconnect the connector from the stop lamp switch assy.
  3. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
  4. Loosen the clevis lock nut.
  5. Adjust the pedal height by turning the pedal push rod.
  6. Tighten the push rod lock nut.
    
    Fig 1: Adjusting Brake Pedal Height (Normal Type)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    
    Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
  7. Install the stop lamp switch assy.
  8. Connect the connector to the stop lamp switch assy.
  9. Push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.), turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off.
  10. After installation, push the brake pedal in 5 - 10 mm (0.20 - 0.39 in.), check that stop lamp lights up.
  11. Install the instrument panel insert sub-assy lower LH and instrument panel finish panel sub-assy lower.
  Fig 2: Adjusting Brake Pedal Height (Link Type)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PEDAL FREE PLAY
1. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
2. Push in the pedal until the beginning of the resistance is felt. Measure the distance, as shown.
  Pedal free play: 1 - 6 mm (0.04 - 0.24 in.)
  
  If incorrect, check the stop lamp switch assy clearance.
  
  If the clearance is OK, then troubleshoot the brake system.
  
  Stop lamp switch clearance:
  
  0.5 - 2.5 mm (0.020 - 0.098 in.)
  
  Fig 3: Checking Brake Pedal Free Play (Normal Type)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Fig 4: Checking Brake Pedal Free Play (Link Type)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake pedal.
  With engine running, depress the pedal and measure the pedal reserve distance, as shown.
  
  Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 63 mm (2.48 in.)
  
  If incorrect, troubleshoot the brake system.
  
  Fig 5: Checking Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002