Toyota Prius: Brake Pedal

Toyota Prius (XW60) 2023-2025 Service Manual / Brake / Brake System (other) / Brake Pedal

Adjustment
Installation

Adjustment

ADJUSTMENT

PROCEDURE

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

(a) Check the brake pedal height.

(1) Measure the shortest distance between the brake pedal pad surface and accelerator pedal pad as shown in the illustration.

*1	Brake Pedal Pad	-	-
*a	Brake Pedal Height	*b	Measuring Plane of Accelerator Pedal Pad
*c	Ruler	*d	35 mm (1.38 in.)

Brake Pedal Height from Accelerator Pedal Pad:

125.3 to 141.3 mm (4.93 to 5.56 in.)

HINT:

If the brake pedal height is not as specified, inspect and adjust the push rod length according to the procedure below.

(b) Adjust the push rod length.

(1) Remove the stop light switch assembly.

Click here

*1	Stop Light Switch Assembly
*2	Master Cylinder Push Rod Nut
*a	Brake Pedal Height
*b	Measuring Plane of Accelerator Pedal Pad

(2) Loosen the master cylinder push rod nut.

(3) Adjust the brake pedal height by turning the push rod.

Brake Pedal Height from Accelerator Pedal Pad:

125.3 to 141.3 mm (4.93 to 5.56 in.)

(4) Tighten the master cylinder push rod nut.

Torque:

25.5 N·m {260 kgf·cm, 19 ft·lbf}

(5) Install the stop light switch assembly.

Click here

2. INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR

NOTICE:

Do not depress the brake pedal after turning the ignition switch to ON.

(a) Inspect the brake pedal stroke sensor.

(1) Read the stroke sensor value without the brake pedal depressed.

Chassis > Brake Booster > Data List

Tester Display
Stroke Sensor

Standard Voltage (without the brake pedal depressed):

0.8 to 1.2 V

HINT:

If the stroke sensor value is not within the standard voltage, adjust the brake pedal stroke sensor.

(b) Adjust the brake pedal stroke sensor.

(1) Remove the No. 1 instrument panel under cover sub-assembly.

Click here

(2) Loosen the 2 nuts.

(3) Read the stroke sensor value in the Data List, and turn the brake pedal stroke sensor slowly to the right or left to adjust the output voltage so that it is within the following range.

Standard Voltage (without the brake pedal depressed):

0.8 to 1.2 V

(4) Tighten the 2 nuts.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

(5) Install the No. 1 instrument panel under cover sub-assembly.

3. PERFORM BRAKE SYSTEM CALIBRATION

HINT:

Perform this procedure only when the brake pedal height or brake pedal stroke sensor has been adjusted.

Click here

4. INSPECT BRAKE PEDAL FREE PLAY

(a) Depress the brake pedal until a slight resistance is felt. Measure the distance as shown in the illustration.

Brake Pedal Free Play:

1.0 to 6.0 mm (0.0394 to 0.236 in.)

HINT:

If the brake pedal free play is not as specified, check the stop light switch clearance.
Click here
If the brake pedal free play is as specified, proceed to the Inspect Brake Pedal Reserve Distance procedure.

*a	Brake Pedal Free Play

5. INSPECT BRAKE PEDAL RESERVE DISTANCE

(a) Turn back the front floor carpet assembly.

(b) With the ignition switch ON (READY), depress the brake pedal and measure the brake pedal reserve distance as shown in the illustration.

*1	Brake Pedal Pad	-	-
*a	Brake Pedal Reserve Distance	*b	Measuring Plane of Column Hole Cover Silencer Sheet
*c	Ruler	*d	35 mm (1.38 in.)
*e	70 mm (2.76 in.)	-	-

Brake Pedal Reserve Distance from Column Hole Cover Silencer Sheet at 300 N (31 kgf, 67.4 lbf):

132 mm (5.20 in.) or more

Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	BRAKE PEDAL PAD	47121		-	-
2	STOP LIGHT SWITCH MOUNTING ADJUSTER	84345	-	-	-
3	BRAKE PEDAL SUPPORT ASSEMBLY	47110		-	-
4	MASTER CYLINDER PUSH ROD CLEVIS	47264	-	-	-
5	ENGINE ROOM MAIN WIRE	82111	-	-	-
6	PUSH ROD PIN	47264A		-	-
7	TEMPORARILY TIGHTEN MASTER CYLINDER PUSH ROD NUT	47262		-	-
8	BRAKE PEDAL RETURN SPRING	47101A		-	-
9	INSPECT AND ADJUST BRAKE PEDAL HEIGHT	-	-	-
10	STOP LIGHT SWITCH ASSEMBLY	84340		-	-
11	INSPECT BRAKE PEDAL FREE PLAY	-	-	-

	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)	*	For use with SST
●	Non-reusable part		Lithium soap base glycol grease

Procedure		Part Name Code
12	NO. 1 AIR DUCT	87211	-	-	-
13	FRONT NO. 1 CONSOLE BOX INSERT	58816D	-	-	-
14	NO. 2 KNEE PROTECTOR BRACKET	55462C	-	-	-
15	LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY	73900		-	-
16	LOWER CENTER INSTRUMENT PANEL FINISH PANEL	55434B	-	-	-
17	LOWER INSTRUMENT PANEL FINISH PANEL ASSEMBLY	55480D	-	-	-
18	COMBINATION METER SUB-ASSEMBLY	-	-	-	-
19	BRAKE PEDAL STROKE SENSOR ASSEMBLY	89510D		-	-
20	CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL	-	-	-	-
21	INSPECT AND ADJUST BRAKE PEDAL STROKE SENSOR	-	-	-
22	NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY	55606	-	-	-
23	COWL SIDE TRIM BOARD LH	62112	-	-	-
24	FRONT DOOR SCUFF PLATE LH	67914	-	-	-
25	PERFORM BRAKE SYSTEM CALIBRATION	-	-	-
26	INSPECT BRAKE PEDAL RESERVE DISTANCE	-	-	-
27	CHECK AND CLEAR DTC	-	-	-	-
28	PERFORM INITIALIZATION AND CALIBRATION	-	-	-

*A	w/ Knee Airbag	*B	w/o Knee Airbag
	Tightening torque for "Major areas involving basic Toyota Prius vehicle performance such as moving/turning/stopping": Nm (kgfcm, ft.*lbf)		Nm (kgfcm, ft.*lbf): Specified torque
●	Non-reusable part	-	-

PROCEDURE

1. INSTALL BRAKE PEDAL PAD

HINT:

Installation is easier after applying a small amount of soapy water.

2. INSTALL STOP LIGHT SWITCH MOUNTING ADJUSTER

3. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY

Torque Wrench Fulcrum Length

(1) Install the nut to the brake pedal support assembly.

(2) Temporarily install the brake pedal support assembly while avoiding the stud bolts of the brake booster with master cylinder assembly and brake booster support base.

(3) Tighten the brake pedal support assembly with the 4 nuts in the order shown in the illustration.

Torque:

12.7 N·m {130 kgf·cm, 9 ft·lbf}

(4) Using SST, tighten the brake pedal support assembly with the bolt.

SST: 09729-00120

SST: 09926-24010

09926-02120

Torque:

Specified tightening torque :

23.6 N·m {241 kgf·cm, 17 ft·lbf}

HINT:

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
Click here
When using SST (fulcrum length of 200 mm (7.87 in.)) torque wrench (fulcrum length of 162 mm (6.38 in.)):
10.6 N*m (108 kgf*cm, 8 ft.*lbf)

4. INSTALL MASTER CYLINDER PUSH ROD CLEVIS

5. INSTALL ENGINE ROOM MAIN WIRE

6. INSTALL PUSH ROD PIN

(1) Apply lithium soap base glycol grease to the push rod pin and installation hole of the brake pedal support assembly.

(2) Connect the master cylinder push rod clevis to the brake pedal support assembly with the push rod pin, and install a new clip as shown in the illustration.

NOTICE:

Be sure to install the push rod pin in the correct direction.

7. TEMPORARILY TIGHTEN MASTER CYLINDER PUSH ROD NUT