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BR-10
BRAKE - BRAKE PEDAL
w/o VSC: BRAKE PEDAL BR1WB-02
Stop Light Switch ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT (W/O VSC)
Pedal height from dash panel:
Standard, access cab:
163.6 to 173.6 mm (6.44 to 6.83 in.)
Double cab:
151.1 to 165.1 mm (5.95 to 6.50 in.)
NOTICE:
Do not adjust the pedal height. Doing so by changing the
Push
Rod push rod length will structurally change the pedal ratio.
2. CHECK AND ADJUST STOP LIGHT SWITCH
(a) Disconnect the connector from the stop light switch.
(b) Turn the stop light switch until it lightly contacts the pedal
stopper.
Pedal Height
(c) Connect the connector to the stop light switch.
(d) Push in the brake pedal 5 to 15 mm (0.20 to 0.59 in), turn
F07754
the stop light switch to lock the nut in the position where
the stop light goes off.
(e) After installation, push in the brake pedal 5 to 15 mm (0.20
to 0.59 in.) and check that the stop light lights up.
(f) After adjusting the stop light switch, check the pedal
height and the pedal free play.
3. CHECK PEDAL FREE PLAY (W/O VSC)
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
Pedal Free Play (b) Push in the pedal by hand until the second point of resis-
tance begins to be felt, then measure the distance as
shown in the illustration.
Pedal free play: 1 to 6 mm (0.04 to 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
R00085 ance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 to 2.4 mm (0.020 to 0.094 in.)
HINT:
The free play to the first point of resistance is due to the play
between the clevis and pin. It is 1 to 3 mm (0.04 to 0.12 in.) at
the pedal.
BR-11
BRAKE - BRAKE PEDAL
4. CHECK PEDAL RESERVE DISTANCE (W/O VSC)
Pedal Reserve Distance
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown in the illustration.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 95 mm (3.74 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.
R00135
w/ VSC: 5. CHECK PEDAL HEIGHT (w/ VSC)
Stop Light Switch
Pedal height from dash panel:
Standard, access cab:
164.0 to 174.0 mm (6.46 to 6.85 in.)
Double cab:
151.1 to 165.1 mm (5.95 to 6.50 in.)
6. IF NECESSARY, ADJUST PEDAL HEIGHT (w/ VSC)
(a) Remove the scuff plate LH, cowl side trim LH, lower finish
panel and No. 2 heater to register duct (see page
BO-111).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
Pedal Height (f) Tighten the clevis lock nut.
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