Brake Pedal: Installation

INSTALL BRAKE PEDAL PAD
1. Install the brake pedal pad onto the brake pedal.
INSTALL BRAKE PEDAL LEVER
1. Apply lithium soap base glycol grease to the 2 brake pedal links and 2 brake pedal shaft collars.
2. Install the 2 brake pedal shaft collars into the brake pedal and brake pedal lever.
3. Install the brake pedal lever with the 2 brake pedal links onto the brake pedal.
4. Install 2 new E-rings onto the brake pedal link.
INSTALL BRAKE PEDAL
1. Apply lithium soap base glycol grease to the 2 collars and 4 brake pedal bushes.
2. Install the 2 collars and 4 brake pedal bushes onto the brake pedal and brake pedal lever.
3. Install the brake pedal onto the brake pedal support with the bolt and nut.
  Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
  
  Fig 1: Locating Brake Pedal Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER
1. Install a new stop light switch mounting adjuster onto the pedal support.
INSTALL BRAKE PEDAL RETURN SPRING
1. Apply lithium soap base glycol grease to the inner surface of the hole in the brake pedal support and brake pedal.
2. Install the return spring onto the brake pedal support and brake pedal.
  
  Fig 2: Identifying Brake Pedal Return Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
1. Install the 4 nuts and the brake pedal support.
  Torque: 14 N*m (145 kgf*cm, 10 ft.*lbf)
  
  Fig 3: Locating Brake Pedal Support Sub-Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE PEDAL SUPPORT REINFORCEMENT
1. Provisionally install the reinforcement onto the brake pedal support with the bolt and nut.
2. Install the reinforcement with the bolt.
  Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
3. Fully tighten the bolt and nut.
  Torque: 34 N*m (350 kgf*cm, 25 ft.*lbf)
INSTALL MASTER CYLINDER PUSH ROD CLEVIS
1. Apply lithium soap base glycol grease to the inner surface of the hole in the brake pedal lever.
2. Install the push rod clevis onto the brake pedal lever with the push rod pin and clip.
  
  Fig 5: Locating Push Rod Clevis Clip And Push Rod Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STOP LIGHT SWITCH
1. Insert the stop light switch into the adjuster until it just touches the brake pedal.
  
  Fig 6: Identifying Stop Light Switch And Adjuster
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE: Do not depress the brake pedal.
2. Make a quarter turn clockwise to install the stop light switch.
  NOTE: Do not depress the brake pedal.
  
  HINT:
  
  The turning torque for installing the stop light switch:
  
  Torque: 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less
3. Check the stop light switch clearance.
  Stop light switch clearance:
  
  0.5 to 2.6 mm (0.020 to 0.102 in.)
  
  Fig 7: Identifying Stop Light Switch Clearance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the connector to the stop light switch.
INSPECT AND ADJUST BRAKE PEDAL (See ON-VEHICLE INSPECTION )
INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY (See INSTALLATION )
CONNECT HOOD LOCK CONTROL LEVER SUB-ASSEMBLY (See INSTALLATION )
INSTALL INSTRUMENT PANEL NO. 1 REGISTER ASSEMBLY (See INSTALLATION )
INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP (See INSTALLATION )
INSTALL COWL SIDE TRIM BOARD (See INSTALLATION )
INSTALL FOOTREST CLIP (See INSTALLATION )
INSTALL FRONT FLOOR FOOTREST (See INSTALLATION )
INSTALL FRONT DOOR SCUFF PLATE (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)