Brake System Checks And Adjustments - Toyota Hilux Surf 1993 Owner's Manual

BR–6
BRAKE SYSTEM – Checks and Adjustments
CHECKS AND ADJUSTMENTS
CHECK AND ADJUSTMENT OF BRAKE PEDAL
1. CHECK THAT PEDAL HEIGHT IS CORRECT, AS SHOWN
PEDAL HEIGHT FROM ASPHALT SHEET:
2WD 148 MM (5.83 IN.)
4WD 145 MM (5.71 IN.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light
switch.
(b) Loosen the stop light switch lock nut and remove
the stop light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push
rod.
(e) Tighten the push rod lock nut.
Torque: 25 N–m (260 kgf–cm, 19 ft–lbf)
(f) Install the stop light switch and turn it until it lightly
contacts the pedal stopper.
(g) Return the stop light switch one turn.
(f) Check the clearance
(A) between stop light switch
and pedal.
Clearance: 0.5 – 2.4mm (0.02 – 0.09 in.)
(i) Tighten the stop light switch lock nut.
(j) Check that the stop light come on when the brake
pedal is depressed, and go off when the brake pedal
is released.
(k) After adjusting the pedal height, check the pedal
free play.
HINT: If clearance
(A) between the stop light switch
and the pedal stopper has been adjusted correctly, the
pedal freeplay will meet the specifications.
3. CHECK THAT PEDAL FREEPLAY IS CORRECT, AS
SHOWN
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the
booster.
(b) (Single booster)
Push in the pedal until the beginning of resistance is
felt. Measure the distance, as shown.
(Tandem booster)
Push in the pedal by hand until the beginning of the
second resistance is felt, measure the distance, as
shown.
Pedal freeplay: 3 – 6mm (0.12 – 0.24 in.)
(Tandem booster)
HINT: The freeplay to the first resistance is due to the
play between the clevis and pin. And it is 1 – 3mm (0.04
– 0.12 in.) on the pedal.