Brake Pedal: Reassembly

INSTALL BRAKE PEDAL BUSHING
1. Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushings.
2. Install the new brake pedal bushings to the brake pedal.
INSTALL BRAKE PEDAL SHAFT COLLAR
1. Apply lithium soap base glycol grease to the ends and sides of brake pedal shaft collar.
2. Install the brake pedal shaft collar to the brake pedal.
INSTALL STOP LIGHT SWITCH CUSHION
INSTALL BRAKE PEDAL PAD
INSTALL BRAKE PEDAL
1. Install the brake pedal to the brake pedal support assembly with the bolt, washer and the nut.
  
  Fig 1: Identifying Brake Pedal Support Assembly And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 37 N*m (375 kgf*cm, 27 ft.*lbf)
INSTALL STOP LIGHT SWITCH ASSEMBLY
1. Temporarily install the stop light switch assembly to the brake pedal support assembly with the stop light switch lock nut.
  HINT:
  
  After checking and adjusting the brake pedal height, tighten the lock nut firmly.
INSTALL BRAKE PEDAL STROKE SENSOR ASSEMBLY
1. New brake pedal stroke sensor assembly:
  1. Install a new brake pedal stroke sensor assembly with the 2 bolts.
    Torque: 9.3 N*m (95 kgf*cm, 82 in.*lbf)
    NOTE:
    Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.
    
    Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor.
  2. Strongly depress the brake pedal and the brake pedal stroke sensor assembly lever set pin will break.
  3. Remove the broken lever set pin.
2. Reuse of brake pedal stroke sensor assembly:
  1. Temporarily install the brake pedal stroke sensor assembly with the 2 bolts.
    NOTE:
    Engage the brake pedal stroke sensor assembly lever with the brake pedal groove.
    
    Check that there is no foreign matter attached to the contact surface of the brake pedal stroke sensor.
    
    Fig 2: Locating Brake Pedal Stroke Sensor Assembly
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002