Toyota Tundra. Manual — part 972

Fig. 17: Identifying No. 3 Brake Pedal Bracket Bolt
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Remove the bolt, nut and No. 3 brake pedal bracket from the brake pedal support.

Fig. 18: Identifying No. 3 Brake Pedal Bracket Bolt And Nut
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

d. Remove the 4 nuts and brake pedal support.

Fig. 19: Identifying Brake Pedal Support Nuts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

12. REMOVE BRAKE PEDAL PAD

a. Remove the brake pedal pad.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

Fig. 20: Identifying Brake Pedal Pad
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ADJUSTMENT

1. CHECK BRAKE PEDAL HEIGHT

a. Check the brake pedal height.

Standard pedal height from dash panel: 179.9 to 189.9 mm (7.08 to 7.48 in.)

If the pedal height is incorrect, check that there is no damage in the brake pedal, brake pedal lever,
brake pedal bracket and dash panel.

Even if there is damage, there is no problem if the reserve distance is within the standard value. If
necessary, replace them.

NOTE:

Do not adjust the pedal height. Doing so by changing the push rod
length will structurally change the pedal ratio.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

Fig. 21: Identifying Brake Pedal Height
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2. CHECK AND ADJUST STOP LIGHT SWITCH ASSEMBLY

HINT:

If the pedal height is incorrect, check and adjust the stop light switch clearance.

a. Disconnect the stop light switch connector.

b. Turn the stop light switch counterclockwise and remove it.

Fig. 22: Identifying Stop Light Switch
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

c. Insert the stop light switch until the body hits the cushion.

d. Make a quarter turn clockwise to install the stop light switch.

HINT:

Due to the inverse screw structure, if the stop light switch is turned clockwise, the stop light switch
moves in the direction to be pulled out.

e. Connect the stop light switch connector.

f. Check the protrusion of the rod.

Standard protrusion of the rod: 1.5 to 2.5 mm (0.0591 to 0.0984 in.)

3. CHECK PEDAL FREE PLAY

NOTE:

When inserting the stop light switch, support the pedal from behind
so that the pedal is not pushed in.

NOTE:

The turning torque for installing the stop light switch should be 1.5
N*m (15 kgf*cm, 13 in.*lbf) or less.

2009 Toyota Tundra

2009 BRAKES Brake - Tundra

a. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the

booster.

b. Push in the brake pedal until the beginning of the resistance is felt. Measure the distance as shown

in the illustration.

Standard pedal free play: 1.0 to 6.0 mm (0.0394 to 0.236 in.)

Fig. 23: Checking Pedal Free Play
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

4. CHECK PEDAL RESERVE DISTANCE

a. Release the parking brake pedal.

b. With the engine running, depress the brake pedal and measure the pedal reserve distance as shown

in the illustration.

Standard pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than
104 mm (4.09 in.)

If incorrect, troubleshoot the brake system (see PROBLEM SYMPTOMS TABLE ).

2009 Toyota Tundra

2009 BRAKES Brake - Tundra