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Brake Pedal Sub-ASSY: Replacement

  1. REMOVE COMBINATION METER ASSEMBLY (See OVERHAUL )
  2. DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
    1. Remove the clip, push rod clevis pin and wave washer, and disconnect the push rod clevis from the brake pedal.
  3. REMOVE BRAKE PEDAL SUPPORT SUB-ASSY
    1. Remove the bolt from the brake pedal support.
    2. Disconnect the stop lamp switch connector.
      Fig 1: Removing Bolt From Brake Pedal Support
      G02633929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 nuts and brake pedal support assy.
      Fig 2: Removing Brake Pedal Support Assy
      G02633930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE BRAKE PEDAL SUB-ASSY
    1. Remove the bolt and nut from the brake pedal support sub-assy.
    2. Remove the brake pedal sub-assy and 2 bushes.
  5. REMOVE STOP LAMP SWITCH ASSY
    1. Loosen the stop lamp switch lock nut.
    2. Remove the stop lamp switch assy from the brake pedal support sub-assy.
  6. REMOVE BRAKE PEDAL PAD
    1. Remove the brake pedal pad from the brake pedal sub-assy.
  7. INSTALL BRAKE PEDAL PAD
    1. Install the brake pedal pad to the brake pedal sub-assy.
  8. INSTALL STOP LAMP SWITCH ASSY
    1. Install the stop lamp switch assy to the brake pedal sub-assy.
  9. INSTALL BRAKE PEDAL SUB-ASSY
    1. Apply the lithium soap base glycol grease to the 2 new bushes on the ends and sides.
    2. Install the brake pedal sub-assy and 2 bushes to the brake pedal support with the bolt and nut.

      Torque: 36.8 N.m (375 kgf.cm, 27 ft.lbf)

  10. INSTALL BRAKE PEDAL SUPPORT SUB-ASSY
    1. Install the brake pedal support assy with the 4 nuts.

      Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf)

    2. Connect the stop lamp switch connector to the stop lamp switch assy.
      Fig 3: Installing Brake Pedal Support Sub-Assy
      G02633931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt to the brake pedal support.

      Torque: 23.6 N.m (240 kgf.cm, 17 ft.lbf)

      Fig 4: Installing Bolt To Brake Pedal Support
      G02633932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
    1. Apply the lithium soap base glycol grease to the push rod clevis pin.
    2. Connect the brake master cylinder push rod clevis with the push rod clevis pin, wave washer and clip.
  12. INSTALL COMBINATION METER ASSEMBLY
  13. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See ADJUSTMENT  )
  14. CHECK PEDAL FREE PLAY (See ADJUSTMENT  )
  15. CHECK PEDAL RESERVE DISTANCE (See ADJUSTMENT  )
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