Brake Light Switch: Adjustments

1. Loosen stop lamp switch mounting nut sufficiently to allow switch to move forward and rearward in adjustment slot.
2. Install brake switch adjustment gage (SA 9303BR) between switch and switch actuator pad on brake pedal arm being sure that plunger protrudes through slot in gage.
3. While pulling up with moderate force on brake pedal assembly, push switch forward against gage.

IMPORTANT: Hold switch perpendicular to actuator pad on brake pedal arm to prevent switch from rotating out of alignment when tightening mounting nut.




4. Tighten switch mounting nut.

Torque: 10 N.m (89 in-lbs)

5. Release brake pedal assembly.
6. With pedal released and adjustment gage still in position, tap gage side-to-side:
c. If gage swings freely side-to-side, proceed to Step 7.
d. If gage sticks or does not swing freely, repeat Steps 1 through 6.




7. With adjustment gage in position, pull up on brake pedal with very light force (approximately 2 lbs.) and tap gage side-to-side:
a. If gage swings freely, repeat Steps 1 through 7.
b. If gage sticks and/or does not swing freely, proceed to Step 8.
8. Inspect switch plunger:
a. If 0.8-1.2 mm (0.03-0.05 in.) of plunger is visible between switch and switch actuator pad on brake pedal arm, switch is correctly adjusted. The height of the rounded crown of the plunger is equivalent to 1 mm (0.040 in.).
b. If more than 1.2 mm (0.05 in.) or less than 0.8 mm (0.3 in.) of plunger is visible, repeat Steps 1 through 8.