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Brake Pedal Support: Installation

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: While the battery is connected, even if the power switch is OFF, the brake control system activates when the brake pedal is depressed or the door courtesy switch turns on. Therefore during servicing of the brake system components, do not operate the brake pedal or open/ close the doors while the battery is connected.
  1. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY 
    1. Install the brake pedal support with the 2 bolts.

      Torque: 19 N*m (195 kgf*cm, 14 ft.*lbf) 

      Fig 1: Locating Brake Pedal Support Bolts
      G04949834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 nuts.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Fig 2: Locating Brake Pedal Support Assembly Nuts
      G04949833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the push rod pin.
    2. Set the master cylinder push rod clevis in place, insert the push rod pin from outside of the vehicle and then install a new clip
      Fig 3: Locating Push Rod Pin And Push Rod Clevis With Clip
      G05781998Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the spring between the pedal and steering column as shown in the illustration.
      Fig 4: Locating Brake Pedal Return Spring
      G04949831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. CONNECT CONNECTORS 
    1. Connect the stop light switch connector and then attach the wire harness clamp
    2. Connect the brake pedal stroke sensor connector
      3. Fig 5: Locating Brake Pedal Stroke Sensor Connector And Stop Light Switch Connector
      G05781979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. CHECK BRAKE DRAG 
  6. CHECK AND ADJUST BRAKE PEDAL HEIGHT  (See ADJUSTMENT  )
  7. ADJUST BRAKE PEDAL STROKE SENSOR  (See ADJUSTMENT  )
  8. CHECK BRAKE PEDAL FREE PLAY  (See ADJUSTMENT  )
  9. CHECK BRAKE PEDAL RESERVE DISTANCE  (See ADJUSTMENT  )
  10. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY 
    1. Install the instrument panel safety pad (see INSTALLATION ).
  11. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  12. INSTALL BATTERY SERVICE HOLE COVER  (See INSTALLATION )
  13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
  14. INSTALL BATTERY SERVICE HOLE COVER LH  (See INSTALLATION )
  15. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY  (See INSTALLATION )
  16. CHECK SRS WARNING LIGHT 
    1. Check the SRS warning light (see DIAGNOSIS SYSTEM ).
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