Brake Pedal: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Inspect brake pedal height.
  Pedal height from asphalt sheet:
  
  M/T: 134.9 to 144.9 mm (5.311 to 5.703 in.)
  
  A/T: 136.0 to 146.0 mm (5.353 to 5.747 in.)
  1. Disconnect the connector from the stop light switch.
  2. Remove the stop light switch.
  3. Loosen the clevis lock nut.
  4. Adjust the pedal height by turning the pedal push rod.
  5. Tighten the push rod lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  6. Install the stop light switch.
  7. Connect the connector to the stop light switch.
  8. Push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.), and turn the stop light switch to lock the nut in the position where the stop light goes off.
  9. After installation, push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.), check that stop light comes on.
  Fig 1: Identifying Brake Pedal Height
  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 in the illustration.
  Pedal free play: 1 to 6 mm (0.04 to 0.24 in.)
  
  If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system.
  
  Stop light switch clearance: 0.5 to 2.4 mm (0.020 to 0.094 in.)
  
  Fig 2: Identifying Brake Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake lever.
  With engine running, depress the pedal and measure the pedal reserve distance, as shown in the illustration.
  
  Pedal reserve distance from asphalt sheet at 294 N (30 kgf, 66 lbf):
  
  without ABS: 78 mm (3.07 in.) or more.
  
  with ABS: 76 mm (2.99 in.) or more.
  
  with VSC: 76 mm (2.99 in.) or more.
  
  If incorrect, troubleshoot the brake system.
  
  Fig 3: Identifying Brake Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002