Automotive / Brake Systems
Brake Pedal Inspection Guide for Toyota BR-5
A technical guide for inspecting and adjusting the brake pedal on the Toyota BR-5. Includes specifications for pedal height, freeplay, and reserve distance, along with adjustment procedures.
Quick answers from the manual
Quick answer
- This manual provides procedures for inspecting and adjusting the brake pedal height, freeplay, and reserve distance for the Toyota BR-5. p. 1, 2
Key actions
- Check pedal height p. 1
- Adjust pedal height p. 1
- Check pedal freeplay p. 1
- Check pedal reserve distance p. 2
Problems and fixes
Incorrect pedal freeplay
Check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system.
p. 1
Incorrect pedal reserve distance
Troubleshoot the brake system.
p. 2Technical specifications
| Parameter | Value | Meaning | Pages |
|---|---|---|---|
| Pedal height | 138.5 – 148.5 mm (5.453 – 5.846 in.) | Standard pedal height from asphalt sheet | p. 1 |
| Push rod lock nut torque | 25 N·m (260 kgf·cm, 19 ft·lbf) | Tightening torque for push rod lock nut | p. 1 |
| Pedal freeplay | 1 – 6 mm (0.04 – 0.24 in.) | Standard pedal freeplay | p. 1 |
| Pedal reserve distance (w/o ABS) | More than 60 mm (2.36 in.) | Minimum reserve distance at 490 N (50 kgf, 110.2 lbf) | p. 2 |
| Pedal reserve distance (w/ ABS) | More than 55 mm (2.17 in.) | Minimum reserve distance at 490 N (50 kgf, 110.2 lbf) | p. 2 |
Where to find it in the PDF
- Brake pedal inspection and adjustment p. 1
- Brake pedal reserve distance inspection p. 2
Table of contents
Manual images
Click an image to enlargeQuick guide from the manual
This document provides the official on-vehicle inspection and adjustment procedures for the brake pedal system on the Toyota BR-5. Users should perform these checks to ensure proper braking performance. Key parameters include pedal height (138.5 – 148.5 mm), pedal freeplay (1 – 6 mm), and pedal reserve distance (> 55-60 mm depending on ABS configuration).
Pedal height inspection and adjustment
Inspection: Measure the pedal height from the asphalt sheet. The standard height is 138.5 – 148.5 mm (5.453 – 5.846 in.).
Adjustment procedure:
- Disconnect the connector from the stop light switch.
- Loosen the stop light switch lock nut and remove the stop light switch.
- Loosen the push rod lock nut.
- Adjust the pedal height by turning the pedal push rod.
- Tighten the push rod lock nut to the specified torque: 25 N·m (260 kgf·cm, 19 ft·lbf).
- Install the stop light switch.
- Push in the brake pedal 5 – 15 mm (0.20 – 0.59 in.), turn the stop light switch to lock the nut in the position where the stop light goes off.
- Connect the connector to the stop light switch.
- After installation, push in the brake pedal 5 – 15 mm (0.20 – 0.59 in.) and check that the stop light lights up.
- After adjusting the pedal height, check the pedal freeplay.
Pedal freeplay inspection
Procedure:
- Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
- Push in the pedal by hand until resistance begins to be felt, then measure the distance.
Specification: The pedal freeplay should be 1 – 6 mm (0.04 – 0.24 in.).
Note: The freeplay to the first resistance is due to the play between the clevis and pin. If the measurement is incorrect, check the stop light switch clearance. If the clearance is correct, troubleshoot the brake system.
Pedal reserve distance inspection
Procedure:
- Release the parking brake.
- With the engine running, depress the pedal and measure the pedal reserve distance from the asphalt sheet at 490 N (50 kgf, 110.2 lbf).
Specifications:
- Without ABS: More than 60 mm (2.36 in.)
- With ABS: More than 55 mm (2.17 in.)
If the reserve distance is incorrect, troubleshoot the brake system.
Manufacturer information
Toyota Motor Corporation
Practical help
Common problems
Incorrect pedal height
Adjust the pedal push rod and lock nut to 25 N·m.
Incorrect pedal freeplay
Check stop light switch clearance; if OK, troubleshoot the brake system.
Incorrect reserve distance
Troubleshoot the brake system.
Before use
- Ensure the vehicle is on a level surface
- Engine must be off for freeplay check
- Engine must be running for reserve distance check
- Release parking brake before checking reserve distance
Specs in practice
- Pedal Height
- 138.5 – 148.5 mm from asphalt sheet
- Push Rod Lock Nut Torque
- 25 N·m (19 ft·lbf)
- Pedal Freeplay
- 1 – 6 mm
- Reserve Distance (w/o ABS)
- More than 60 mm
- Reserve Distance (w/ ABS)
- More than 55 mm
Images and diagrams
- Diagrams show the push rod and stop light switch location for height adjustment.
- Diagrams illustrate the measurement point for pedal freeplay.
- Diagrams illustrate the measurement point for pedal reserve distance.
Model compatibility
- Reserve distance specifications differ based on whether the vehicle is equipped with ABS.
Manual page author
Michael Turner
Technical manual editor
Reviews PDF manuals for structure, safety notes, and practical product details so readers can find the right information quickly.