BRAKE PEDAL CHECK AND ADJUSTMENT


caution Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch. In addition, do not use gloves which have grease on them.

BRAKE PEDAL HEIGHT
1.Turn up the floor carpet under the brake pedal.
2.Remove the stop lamp switch (Refer to ).

3.Use a needle or similar tool to measure the dimension (distance from the dash panel pad surface to the dash panel).
4.Measure the dimension (distance from the pedal pad surface to the dash panel pad surface).
5.Make sure that the total of the dimension measured in Steps 2 and 3 (brake pedal height) is within the standard value.
Standard value (A):
293.7 - 298.7 mm <LHD>
264.8 - 270.8 mm <RHD>


6.When the brake pedal height is not within the standard value, adjust the brake pedal in the following procedure.
(1) Disconnect the stop lamp switch connector.
(2) Loosen the stop lamp switch by turning it anti-clockwise by approximately 1/4 turn.
(3) Loosen the lock nut of operating rod, then turn the serrated section of operating rod using the pliers to adjust the brake pedal height to the standard value.
(4) Press in the stop lamp switch until the thread section of stop lamp switch comes in contact with the pedal stopper. Then, secure the stop lamp switch by turning it clockwise by approximately 1/4 turn. While doing this, pull and hold the brake pedal by hand.
(5) Check that the clearance between the stop lamp switch and the pedal stopper is as shown in the figure.
(6)
caution Make sure that the stop lamp is not illuminated when the brake pedal is not depressed.
Connect the stop lamp switch connector.
7.Return the carpet, etc.

BRAKE PEDAL FREE PLAY

1.Turn the ignition switch to the LOCK (OFF) position, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range.
Standard value (B): 3 - 8 mm
2.If the brake pedal play is not within the standard value, check the following, and adjust or replace if necessary:

  • Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod
  • Brake pedal height
  • Installation position of the stop lamp switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR BOARD
1.Turn up the carpet, etc. under the brake pedal.

2.Start the engine, depress the brake pedal with approximately 500 N of force, and measure the clearance between the brake pedal and the floor board.
<Vehicles for Thailand>
Standard value (C):
73 mm or more
<Except vehicles for Thailand>
Standard value (C):
75 mm or more <LHD>
80 mm or more <RHD>
3.If the clearance between the brake pedal and the floor is not within the standard value, check the brake lines for air-lock, the disc brake pad thickness or the drum brake lining thickness, and the parking brake for dragging. Adjust or replace defective part(s) if necessary.
4.Return the carpet etc. to its original position.