Brake Pedal Assy: Testing and Inspection

BRAKE PEDAL CHECK AND ADJUSTMENT





1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated. If the brake pedal height is not within the standard value, follow the procedure below.
Standard value: 163.5 - 166.5 mm (6.44 - 6.56 inch)





1. Disconnect the stop light switch connector.
2. Adjust the brake pedal height by turning the operating rod with pliers (with the operating rod lock nut loosened), until the correct brake pedal height is obtained.
3. Secure by tightening the lock nut of the operating rod.





4. Push the stop light switch in the direction of the pedal stroke until it stops. (The switch will slide if it is pushed firmly.)
5. Lift up the pedal until the operating rod is fully extended, and then slide the stop light switch back to the required position. Adjust the position of the switch by turning it until the distance shown in the illustration is correct.
6. Connect the connector of the stop light switch.
7. Check that the stop light is not illuminated with the brake pedal unpressed.





3. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value range.
Standard value: 3 - 8 mm (0.12 - 0.31 inch)
If the free play exceeds the standard value, it is probably due to excessive play between the retaining ring bolt and brake pedal arm. Check for excessive clearance and replace faulty parts as required.





4. Start the engine, depress the brake pedal with approximately 490 N (110 lbs.) of force, and measure the clearance between the brake pedal and the floorboard.
Standard value: 80 mm (3.15 inch) or more
If the clearance is outside the standard value, check for air trapped in the brake line, clearance between the lining and the drum and dragging in the parking brake. Adjust and replace defective parts as required.
5. Turn back the carpet to its original position.