LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2003 >> ES 300 >> Repair and Diagnosis >> External Pages >> Different car >> Section 387 (Anti-Lock Brake System) >> Brake Pedal Support ASSY >> Overhaul

Brake Pedal Support ASSY: Overhaul

WARNING: This page is about a different car, the 2004 Toyota Camry Solara. However, it is still accessible from the selected car via links, so may be relevant.
  1. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSY (SEE  REPLACEMENT  ) 
  2. REMOVE BRAKE PEDAL RETURN SPRING 
  3. REMOVE PUSH ROD PIN 
    1. Remove the clip and push rod pin.
  4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSY 
    1. Disconnect the stop lamp switch connector.
    2. Remove the 2 bolts, 4 nuts and brake pedal support sub-assy.
  5. REMOVE STOP LAMP SWITCH ASSY 
    1. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
  6. REMOVE BRAKE PEDAL SUB-ASSY 
    1. Remove the nut, bolt and brake pedal sub-assy from brake pedal support sub- assy.
  7. REMOVE BRAKE PEDAL PAD 
  8. REMOVE BRAKE PEDAL BUSH 
    1. Remove the 2 brake pedal bushes from brake pedal sub-assy.
  9. REMOVE STOP LAMP SWITCH CUSHION 
  10. INSTALL STOP LAMP SWITCH CUSHION 
  11. INSTALL BRAKE PEDAL BUSH 
    1. Apply lithium soap base glycol grease to the parts indicated by arrows (see COMPONENTS ).
    2. Install 2 new brake pedal bushes to brake pedal sub-assy.
  12. INSTALL BRAKE PEDAL PAD 
  13. INSTALL BRAKE PEDAL SUB-ASSY 
    1. Install the brake pedal sub-assy with the bolt and nut.

      Torque:  37 N.m (375 kgf.cm, 27 ft.lbf)

  14. INSTALL STOP LAMP SWITCH ASSY 
    1. Install the stop lamp switch assy with the stop lamp switch lock nut.

    HINT:

    After adjusting the brake pedal height, torque the lock nut.

  15. INSTALL BRAKE PEDAL SUPPORT SUB-ASSY 
    1. Install the brake pedal support sub-assy with the 2 bolts and 4 nuts.

      Torque: 

      • Bolt:  20 N.m (204 kgf.cm, 15 ft.lbf)
      • Nut:  13 N.m (130 kgf.cm, 9 ft.lbf)
  16. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the parts indicated by arrows (see COMPONENTS ).
    2. Install the push rod pin and clip.
    3. Connect the stop lamp switch connector.
  17. INSTALL BRAKE PEDAL RETURN SPRING 
  18. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSY (SEE  REPLACEMENT  ) 
  19. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE  BRAKE PEDAL SUPPORT ASSY   )
  20. CHECK PEDAL FREE PLAY (SEE  BRAKE PEDAL SUPPORT ASSY  ) 
  21. CHECK PEDAL RESERVE DISTANCE (SEE  BRAKE PEDAL SUPPORT ASSY  ) 
  22. INSPECT SRS WARNING LIGHT (SEE  DIAGNOSTIC PROCEDURE  ) 
scientia non olet · About LEMON Manuals