Brake Pedal Assy: Testing and Inspection
BRAKE PEDAL HEIGHT INSPECTION1. Remove the brake switch.
2. Measure length L.
^ If length L is within the specification, reinstall the switch.
Length L
21.7 - 22.0 mm (0.86 - 0.87 inch)
BRAKE PEDAL HEIGHT ADJUSTMENT
1. Loosen locknut B and turn self-locknut A until it does not contact the pedal.
2. Loosen locknut D and turn rod C to adjust the height.
3. Tighten locknut D.
Tightening torque
24 - 34 Nm (2.4 - 3.5 kgf-m, 18 - 25 ft. lbs.)
4. Turn self-locknut A so that the clearance M is 0.1 - 1.0 mm (0.004 - 0.039 inch).
5. Tighten locknut B.
Tightening torque
9.9 - 14.7 Nm (100 - 150 kgf-cm, 87 - 130 inch lbs.)
Caution
^ When the brake pedal height is adjusted, a new brake switch must be used.
^ The new switch can be adjusted only once.
^ Pulling or pushing the tip of the new brake switch can damage the inner parts.
6. Install a new brake switch.
Note The new brake switch projection height is adjusted automatically in step 7.
7. Pull the brake pedal until you hear the tip of the brake switch clicks.
8. Inspect the pedal play and the brake light operation.
^ If the brake light does not operate, replace the brake switch and repeat step 6 - 8.
PEDAL PLAY INSPECTION
1. Depress the pedal a few times to eliminate the vacuum in the system.
2. Remove the snap pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin.
3. Gently depress the pedal by hand (until resistance is felt) and check the free play.
Pedal play
4 - 12 mm (0.16 - 0.47 inch)
PEDAL PLAY ADJUSTMENT
1. Remove the snap pin and the clevis pin.
2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal.
3. Install the clevis pin and the snap pin.
4. Check the pedal height and the brake light operation.
Tightening torque
24 - 34 Nm (2.4 - 3.5 kgf-m, 18 - 25 ft. lbs.)
PEDAL-TO-FLOOR CLEARANCE INSPECTION
1. Verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 590 N (60 kgf, 130 lbs.).
^ If the distance is less than specified, inspect for the following problems:
- Air in brake system
- Malfunction of automatic adjuster
- Worn pads
Pedal-to-floor clearance
95 mm (3.8 inch) min.