Brake Pedal Assy: Service and Repair

Brake Pedal

REMOVAL

MT MODEL
1) Remove the steering column.
2) Disconnect the connector from clutch switch.
3) Disconnect the connector from stop light switch.
4) Turn the stop light switch counterclockwise and remove the switch.





5) Remove the clevis pin which secures the pedal and operating rod.





6) Remove the nut which secures the clutch master cylinder.
7) Remove the bolt and nut which secures the pedal bracket.





AT MODEL
1) Remove the steering column.
2) Disconnect the connector from stop light switch.
3) Turn the stop light switch counterclockwise and remove the switch.





4) Remove the clevis pin which secures the brake pedal and operating rod.





5) Remove the bolt and nut which secures the brake pedal bracket.





INSTALLATION

CAUTION:
- Perform the following steps for the stop light switch.
- Do not install the stop light switch before step 2). Installing the stop light switch before step 2) may result in the switch falling off, remaining illuminated constantly, or an illumination fault.

1) Install the bolt and nut which secure the brake pedal bracket.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
2) Install clevis pin and snap pin which secure the operating rod to the brake pedal.

NOTE:
- Replace with a new clevis pin.
- Apply a thin coat of KOPR-KOTE (Part No. 003603001) to the clevis pin.





3) Make sure that the switch clip (gray) is securely installed to the brake pedal bracket.





4) While pulling up the brake pedal, insert the stop light switch until it reaches the stopper (brown) at the brake pedal side. Turn the stop light switch clockwise and install the switch.








5) Connect the stop light switch connector.
6) Check that the brake light operate properly.
7) Check the brake pedal after installation.

INSPECTION
1) Move the brake pedal pads in a horizontal direction with a force of approx. 10 N (1 kgf, 2 lbf), and check that the pedal deflection is in the range of specifications.

CAUTION:
If excessive deflection is noted, replace with a new bushing.

Deflection of brake pedal:
Limit
5.0 mm (0.197 in) or less





2) Check the position of the pedal pad.
Pedal height L:
150 - 160 mm (5.91 - 6.29 in)
Brake pedal free play A:
0.5 - 2 mm (0.020 - 0.079 in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lbf).]





3) If out of specification, perform the procedures below to adjust.
4) Remove the stop light switch.
5) Loosen the lock nut of the brake booster operating rod, and rotate the rod to adjust the pedal height L to be within the standard value.
6) Tighten the lock nut.
Tightening torque:
22 Nm (2.2 kgf-m, 16.2 ft-lb)
7) Install the stop light switch.