Curiosii for ever!: Car repair manuals for everyone.
Home >> Toyota Truck >> 2005 >> Sienna AWD V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Brakes and Traction Control >> Brake Pedal Assy >> Service and Repair

Brake Pedal Assy: Service and Repair






BRAKE PEDAL SUPPORT ASSEMBLY
REPLACEMENT
1. SEPARATE BATTERY NEGATIVE TERMINAL
2. REMOVE FRONT DOOR SCUFF PLATE LH
3. REMOVE COWL SIDE TRIM BOARD LH
4. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER LH
a. Remove the 2 bolts and instrument panel finish panel sub-assembly lower LH.
5. REMOVE INSTRUMENT PANEL SAFETY PAD INSERT SUB-ASSEMBLY NO.1
a. Remove the 4 bolts and instrument panel safety pad insert sub-assembly No.1.





6. LOOSEN BRAKE PEDAL SHAFT
a. Loosen the 2 brake pedal shafts.





7. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY
a. Remove the 4 nuts and brake pedal support sub-assembly.
b. Using needle-nose pliers, remove the tension spring.
c. Remove the clip and clevis pin from the brake pedal lever.





d. Remove the 2 bolts from the brake pedal bracket No.3.
e. Remove the stop lamp switch harness clamp from the brake pedal support sub-assembly.
f. Disconnect the stop lamp switch connector.
8. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Turn the stop lamp switch assembly counterclockwise and remove the stop lamp switch assembly.
b. Remove the stop lamp switch mounting adjuster from the brake pedal support sub-assembly.
9. REMOVE STOP LAMP SWITCH CUSHION
a. Remove the stop lamp switch cushion from the brake pedal sub-assembly.
10. REMOVE BRAKE PEDAL
a. Remove the 2 brake pedal shafts, 2 nuts and brake pedal from the brake pedal support sub-assembly.
11. REMOVE BRAKE PEDAL BUSH
a. Remove the 4 brake pedal busies from the brake pedal.
12. REMOVE BRAKE PEDAL SHAFT COLLAR
a. Remove the 2 brake pedal shaft collars from the brake pedal.





13. REMOVE PUSH ROD PIN
a. Using a screwdriver, remove the 2 E-rings, 2 push rod pins and 2 plates from the brake pedal.
b. Remove the 2 push rod busies.
14. REMOVE BRAKE PEDAL PAD
a. Remove the brake pedal pad to the brake pedal sub-assembly.
15. INSTALL BRAKE PEDAL PAD
a. Install the brake pedal pad to the brake pedal sub-assembly.
16. INSTALL PUSH ROD PIN
a. Apply lithium soap base glycol grease to inside surface of 2 new push rod busies.
b. Install the 2 new push rod busies.
c. Install the 2 push rod pins with the 2 plate to the brake pedal.
d. Using needle-nose pliers, install the 2 new E-rings to the 2 push rod pins.

NOTICE: Install the E-ring securely to the grooves of the push rod pin.

17. INSTALL BRAKE PEDAL BUSH
a. Apply lithium soap base glycol grease to inside surface of 4 new brake pedal busies.
b. Install the 4 brake pedal busies to the brake pedal.
18. INSTALL BRAKE PEDAL SHAFT COLLAR
a. Apply the lithium soap base glycol grease to inside surface of 2 brake pedal shaft collars.
b. Install the 2 brake pedal shaft collars to the brake pedal.
19. INSTALL BRAKE PEDAL
a. Install the 2 brake pedal shafts, 2 nuts, brake pedal and brake pedal bracket No.3 to the brake pedal support sub-assembly.
20. INSTALL STOP LAMP SWITCH CUSHION
a. Install the stop lamp switch cushion to the brake pedal sub-assembly.
21. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Install the stop lamp switch mounting adjuster to the brake pedal support sub-assembly.
b. Install the stop lamp switch assembly until the body hits the cushion.
c. Make a quarter turn clockwise to install the stop lamp switch assembly.

NOTICE: The turning torque for installing the stop lamp switch assembly.

Torque: 1.5 Nm (15 kgf-cm, 13 inch lbs.) or less

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





22. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
a. Install the brake pedal support sub-assembly with the 4 nuts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
b. Install the clip and clevis pin to the brake pedal lever.
c. Using needle-nose pliers, install the tension spring.





d. Install the 2 bolts to the brake pedal bracket No.3.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
e. Install the stop lamp switch harness clamp to the brake pedal support sub-assembly.
f. Connect the stop lamp switch connector.





23. FULLY TIGHTEN BRAKE PEDAL SHAFT
a. fully tighten the 2 brake pedal shafts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
24. INSTALL INSTRUMENT PANEL SAFETY PAD INSERT SUB-ASSEMBLY NO.1
a. Install the instrument panel safety pad insert sub-assembly No.1 with the 4 bolts.
25. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER LH
a. Install the instrument panel finish panel sub-assembly lower LH with the 2 bolts.
26. INSTALL COWL SIDE TRIM BOARD LH
27. INSTALL FRONT DOOR SCUFF PLATE LH
28. INSPECT BRAKE PEDAL HEIGHT
29. CHECK PEDAL FREE PLAY
30. CHECK PEDAL RESERVE DISTANCE



pro multis · Curiosii