Attachment III - Technical Information

OVERVIEW

This document details the procedure for inspecting the distance between the brake pedal and accelerator pedal and adjusting the distance if it is not within specification. A special tool has been developed that serves two functions: 1) to check the space between the two pedals and 2) to set the distance between the two pedals. The tool is clearly marked "CHECKING GAUGE" and "SETTING GAUGE".

The instructions that follow detail the proper use of the tool. Make sure the correct side faces toward the accelerator pedal for inspection and adjustment as indicated in the procedure.

INSPECTION

CAUTION:
Failure to move the adjustable pedals and driver seat to the rearward most position will invalidate the inspection.

1. Move the adjustable pedals and the driver seat to their full rearward positions (toward the rear of the vehicle).

2. NOTE: Make sure that the rubber pad on the brake pedal is fully seated before installing the special tool.





Install the special tool onto the brake pedal by sliding it over the top of the pedal. Make sure that the "CHECKING GAUGE" side is toward the accelerator pedal and the tool is fully seated onto the brake pedal. With the tool in place and the pedals resting freely (keep your hands off the pedals while performing this check), inspect for any clearance between the tool and the accelerator pedal. See Figure 1.

^ If there is any clearance between the tool and the pedal, no repair is required. Remove the special tool and move the adjustable pedals and driver seat to their original positions. Release the vehicle.

^ If there is no clearance (i.e., the tool and the accelerator pedal are touching), remove the special tool and continue with Pedal Adjustment.

PEDAL ADJUSTMENT





1. Loosen the accelerator pedal and brake pedal pivot bolt nuts. See Figure 2.





2. Slide the special tool up onto the brake pedal with the "SETTING GAUGE" side toward the accelerator pedal. By hand, push the accelerator pedal to the right to gain enough clearance to fully seat the tool onto the brake pedal. Once the tool is fully seated, make sure the edge is in contact with the accelerator pedal. See Figure 3.

3. Tighten the accelerator pedal and brake pedal pivot bolt nuts to 24 Nm (18 lb-ft).

4. Remove the special tool from the brake pedal.

5. Reinstall the tool onto the brake pedal with the "CHECKING GAUGE" side toward the accelerator pedal. With the tool in place and the pedals resting freely (keep your hands off the pedals while performing this check), inspect for any clearance between the tool and the accelerator pedal. See Figure 1.

^ If there is any clearance between the tool and the pedal, remove the special tool and continue with Step 9.

^ If there is no clearance (i.e., the tool and the accelerator pedal are touching), continue with Step 6.

6. Remove the special tool and loosen, but do not remove, the five (5) pedal bracket anchor nuts and the two (2) anchor bolts.





NOTE:
Some vehicles may have six (6) pedal bracket anchor nuts. See Figure 4.

7. Install the special tool onto the brake pedal with the "SETTING GAUGE" side facing the accelerator pedal. Make sure the tool is fully seated onto the brake pedal, then tighten the five (5) (or six [6]) bracket anchor nuts and the two (2) anchor bolts to 25 Nm (18 lb-ft) and remove the special tool.

8. Recheck the adjustment by installing the special tool onto the brake pedal with the "CHECKING GAUGE" side facing the accelerator pedal. With the tool in place and the pedals resting freely (keep your hands off the pedals while performing this check), inspect for any clearance between the tool and the accelerator pedal.

^ If there is any clearance between the tool and the pedal, remove the special tool and continue with Step 9.

^ If there is no clearance (i.e., the tool and the accelerator pedal are touching), remove the special tool and call the Special Service Support Center for further instructions.

9. Make sure the rubber pad on the brake pedal is fully seated and return the adjustable pedals and the driver seat to their original positions. Release the vehicle.