Brake Pedal Assy: Service and Repair

Brake Pedal

REMOVAL
1. MT MODEL
1. Remove the steering shaft.
2. Disconnect the connectors (for stop light switch, etc.) from pedal bracket.
3. Remove the clevis pin which secures the lever to push rod.
4. Remove the nut which secures the clutch master cylinder.
5. Remove the accelerator pedal.
6. Remove the bolts and nuts which the secure pedal bracket.





2. AT MODEL
1. Disconnect the ground cable from battery.
2. Remove the instrument panel lower cover from instrument panel.
3. Remove the clevis pin which secures the brake pedal to brake booster operating rod. Also disconnect the stop light switch connector.
4. Remove the four bolts and four nuts which secure the brake pedal to pedal.





INSTALLATION
1. Install in the reverse order of removal.

CAUTION:
^ If the cable clamp is damaged, replace it with a new one.
^ Never fail to cover the outer cable end with boot.
^ Always use new clevis pins.

2. Adjust the clutch pedal
3. Inspect the brake pedal after installation

DISASSEMBLY
1. MT MODEL
1. Remove the brake switch.
2. Remove the clutch pedal.
3. Remove the clutch master cylinder bracket.





4. Remove the bushing, spring and stopper.





5. Remove the brake pedal pad.

2. AT MODEL
1. Remove the brake switch.
2. Unbolt, and then remove the brake pedal.





3. Remove the bushing, spacer and spring.





4. Remove the brake pedal pad.

ASSEMBLY
1. Attach the stop light switch, etc. to pedal bracket temporarily.
2. Clean the inside of bores of clutch pedal and brake pedal, apply grease, and set the bushings into bores.
3. Align bores of the pedal bracket, clutch pedal and brake pedal, attach the brake pedal return spring, and then install the pedal bolt.

NOTE: Clean up the inside of bushings and apply grease before installing spacer.

Tightening torque:
T. 30 Nm (3.1 kgf-m, 22.1 ft. lbs.)





4. Adjust the stop light switch position after installing the brake pedal to vehicle.

INSPECTION
1. Move the brake and clutch pedal pads in the lateral direction with a force of approximately 10 Nm (1 kgf, 2 ft. lbs.) to ensure pedal deflection is in specified range.

CAUTION: If excessive deflection is noted, replace the bushings with new ones.

Deflection of brake and clutch pedal.
Service limit 5.0 mm (0. 197 inch) or less








2. Check the position of pedal pad.
Pedal height L: 148 mm (5.83 inch)
Brake pedal free play 0.5 - 2.0 mm (0. 02 - 0.08 inch) [Depress brake pedal pad with a force of less than 10 Nm (1 kgf, 2 ft. lbs.).]





3. If it is not within specified value, adjust it by adjusting the brake booster operating rod length.