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





5) Remove the nut which secures the clutch master cylinder.
6) 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) Remove the clevis pin which secures the brake pedal and operating rod.





4) Remove the bolts and nuts which secure the brake pedal bracket.





INSTALLATION

1) Install the bolt and nut which secure the brake pedal bracket.

Tightening torque:
18 Nm (1.84 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) Connect the stop light switch connector.
4) Check that the brake light operate properly.
5) 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 the inspection result is not within the specification, loosen the lock nuts of brake booster operating rod, and rotate the rod to adjust the pedal height L within the specification.
4) Tighten the lock nut.

Tightening torque:
22 Nm (2.24 kgf-m, 16.2 ft-lb)