Figure 10.18. Brake pedal fastening elements: 1 – bolt; 2 – flat washer; 3 – spring washer; 4 – nut; 5 – bushings; 6 – cotter pin; 7 – return spring; 8 – pedal cover; 9 – brake pedal; 10 – pin with a head and a hole for a cotter pin; 11 – axis
Remove the cotter pin and take out the pin with the hole for the cotter pin (figure 10.18).
Remove the tie bolt, nut and washers.
Disconnect the return spring and remove the brake pedal.
Inspect components for worn bushings, bent or damaged pedal, worn or deteriorated pedal pad, warped pinch bolt, and damaged or weakened return spring.
Before installation, lubricate the contact surfaces of the tie bolt, bushings and pin with a white lithium-based lubricant.
Installation is carried out in the reverse order of removal
After installation, adjust the brake pedal position and free play as follows.
Measure the brake pedal installation height, which should be between 21.41 and 21.51 mm.
Figure 10.19. Brake pedal positions: a – pedal installation height; b – free travel of the pedal; c – distance of the pedal from the floor; 1 – brake light switch; 2 – brake light switch lock nut; 3 – pusher; 4 – pusher lock nut
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If adjustment is necessary, disconnect the connector from the brake light switch, loosen the lock nut of the switch and rotate the switch housing so that the pedal installation height (figure 10.19) corresponded to the required. Tighten the lock nut and connect the connector to the switch.
With the engine off, press the brake pedal several times to relieve the vacuum in the brake booster, then check the brake pedal free play; it should be between 71.12 and 88.9 mm. If adjustment is necessary, loosen the lock nut and rotate the push rod. Tighten the locknut when the required free play is reached.
With the engine off, press the pedal as far as possible and measure the distance between the pedal and the floor. When the load is 53 kgf, the distance should be at least 11.5 cm. If the distance is less, first bleed the air from the hydraulic brake system, then check the condition of the rear drum brake shoes and the automatic adjuster. Make sure the brake hoses do not bulge under pressure.