Adjustment [08/2014 - ]

1. Check the brake pedal height.
   Fig 1: Measuring Brake Pedal Height

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Pedal height from Floor panel

   158.8 to 168.8 mm (6.25 to 6.46 in.)

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   *1	Rod Operating Adapter
   *2	Stop Light Switch Assembly
   *3	Floor Panel
   *a	Pedal Height

   NOTE:

   Do not adjust the pedal height. Doing so by changing the push rod length will structurally change the pedal ratio.

   If the pedal height is incorrect, adjust the rod operating adapter length.

2. Adjust the rod operating adapter length.
   Fig 2: Identifying Rod Operating Adapter Length

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Remove the clip and clevis pin.
   2. Loosen the clevis lock nut.
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      *1	Clevis Lock Nut

   3. Adjust the rod operating adapter length by turning the pedal push rod clevis.

      Rod operating adapter length "A"

      236.3 to 237.3 mm (9.30 to 9.34 in.)

   4. Tighten the clevis lock nut.

      Torque: 26 N*m (260 kgf*cm, 19 ft.*lbf) 

   5. Install the clip and clevis pin.

      If the pedal height is incorrect even if the rod operating adapter is adjusted, check that there is no damage to the brake pedal, brake pedal lever, brake pedal bracket or floor panel.

      • Even if there is damage, there is no problem if the reserve distance is within the standard value.
      • If necessary, replace the clip.

HINT: 

If the pedal height is incorrect, check and adjust the stop light switch clearance.

1. Disconnect the stop light switch assembly connector from the stop light switch assembly.
2. Turn the stop light switch assembly counterclockwise and remove the stop light switch assembly.
3. Insert the stop light switch assembly until the body hits the cushion.
   Fig 3: Identifying Stop Light Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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   *1	Stop Light Switch

   NOTE:

   When inserting the stop light switch assembly, support the pedal from behind so that the pedal is not pushed in.

4. Make a quarter turn clockwise to install the stop light switch assembly.
   NOTE:

   The turning torque for installing the stop light switch should be 1.5 N*m (15 kgf*cm, 13 in.*lbf) or less.

   HINT: 

   Due to the inverse screw structure, if the stop light switch assembly is turned clockwise, the stop light switch assembly moves in the direction to be pulled out.

5. Connect the stop light switch connector to the stop light switch assembly.
6. Check the protrusion of the rod.

   Protrusion of the rod

   1.5 to 2.5 mm (0.0591 to 0.0984 in.)

7. Install the clevis pin and clip.
8. After adjusting the pedal height, check the pedal free play.

1. Push in the pedal until the resistance is felt. Measure the distance.
   Fig 4: Identifying Pedal Free Play

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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   *a	Pedal Free Play

   Pedal free play

   1 to 6 mm (0.0394 to 0.236 in.)

   HINT: 

   Check the brake pedal free play at the same location as that used when checking the brake pedal height.

1. Release the parking brake pedal.
   Fig 5: Identifying Pedal Reserve Distance

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   With the engine running, depress the pedal and measure the pedal reserve distance.

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   *a	Pedal Reserve Distance

   Pedal reserve distance from floor panel at 490 N (50 kgf, 110.2 lbf)

   More than 92 mm (3.62 in.)

   If incorrect, troubleshoot the brake system.

   HINT: 

   Insert a ruler into the slit to measure the pedal reserve distance.