Toyota BR-5 Brake Pedal Inspection and Adjustment Guide

Quick guide from the manual

This document provides the official on-vehicle inspection and adjustment procedures for the brake pedal system of the 1997 Toyota Paseo (BR-5). It details how to verify pedal height, freeplay, and reserve distance to ensure proper braking performance.

Brake pedal height inspection and adjustment

The standard pedal height from the asphalt sheet should be between 138.5 and 148.5 mm (5.453 – 5.846 in.). If adjustment is required:

• Disconnect the stop light switch connector.
• Loosen the stop light switch lock nut and remove the switch.
• Loosen the push rod lock nut.
• Adjust the pedal height by turning the pedal push rod.
• Tighten the push rod lock nut to 25 N·m (260 kgf·cm, 19 ft·lbf).
• Reinstall the stop light switch.
• Push the pedal 5 – 15 mm (0.20 – 0.59 in.) and adjust the switch position until the stop light turns off.
• Reconnect the connector and verify the stop light activates when the pedal is pushed 5 – 15 mm.
• Check the pedal freeplay after adjustment.

Checking pedal freeplay

To check the freeplay, stop the engine and depress the brake pedal several times to eliminate vacuum in the booster. Push the pedal by hand until resistance is felt and measure the distance. The standard freeplay is 1 – 6 mm (0.04 – 0.24 in.). If the measurement is incorrect, check the stop light switch clearance.

Checking pedal reserve distance

Release the parking brake and start the engine. Depress the pedal with a force of 490 N (50 kgf, 110.2 lbf) and measure the distance from the asphalt sheet:

• Without ABS: More than 60 mm (2.36 in.)
• With ABS: More than 55 mm (2.17 in.)

If the reserve distance is incorrect, the brake system requires further troubleshooting.