Brake Pedal Inspection and Adjustment Guide for 2000 Toyota Tacoma

Quick Guide from the Manual

This document outlines the official inspection and adjustment procedures for the brake pedal on a 2000 Toyota Tacoma. Key specifications include a pedal height of 154.6–164.6 mm, a pedal freeplay of 3–6 mm, and a pedal reserve distance of more than 72 mm. Always ensure the engine is off and vacuum is removed from the booster before performing freeplay checks.

Brake Pedal Height Inspection and Adjustment

Inspection

Measure the pedal height from the asphalt seat. The standard range is 154.6 – 164.6 mm (6.087 – 6.480 in.).

Adjustment

1. Disconnect the connector from the stop light switch.
2. Loosen the stop light switch lock nut and remove the stop light switch.
3. Loosen the push rod lock nut.
4. Adjust the pedal height by turning the pedal push rod.
5. Tighten the push rod lock nut to 25 N·m (260 kgf·cm, 19 ft·lbf).
6. Install the stop light switch.
7. Push the brake pedal in 5–15 mm (0.20 – 0.59 in.), then turn the stop light switch to lock the nut in the position where the stop light goes off.
8. Push the brake pedal in 5–15 mm (0.20 – 0.59 in.) and check that the stop light illuminates.
9. After adjusting the pedal height, check the pedal freeplay.

Pedal Freeplay Check

1. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
2. Push in the pedal by hand until the second resistance begins to be felt.
3. Measure the distance. The standard pedal freeplay is 3 – 6 mm (0.12 – 0.24 in.).
4. If the freeplay is correct, check the stop light switch clearance (0.5 – 2.4 mm). If the clearance is correct but the system fails, troubleshoot the brake system.

Pedal Reserve Distance Check

1. Release the parking brake.
2. With the engine running, depress the pedal.
3. Measure the pedal reserve distance at 490 N (50 kgf, 110.2 lbf).
4. The distance must be more than 72 mm (2.83 in.). If the distance is incorrect, troubleshoot the brake system.