Brake Pedal Assy: Adjustments

Fig. 18 Measuring Brake Pedal Height Dimension ``A'':

1. Measure brake pedal height dimension "A," as shown.
2. Standard height is 6.2-6.4 inches on Colt Wagon, 6.6-6.7 inches on Colt and Summit, 6.9-7.1 inches on Laser and Talon, and 7.0-7.2 inches on Stealth.

Fig. 19 Adjusting Brake Pedal Height:

Fig. 20 Measuring Stop Light Switch Reference Dimension ``B'':

Fig. 21 Measuring Brake Pedal Free Play Dimension ``C'':

Fig. 22 Measuring Clearance Between Brake Pedal & Floor Board Dimension ``D'':

3. If pedal height is not within specifications, adjust as follows:
a. Disconnect stop light switch electrical connector, then loosen locknut and move stop light switch to a position were it does not contact brake pedal arm.
b. Adjust brake pedal height by turning operating rod with pliers until correct brake pedal height is obtained.
c. On Colt and Summit models, remove clevis pin that connects master cylinder push rod and clutch pedal, then the nuts that secure clutch master cylinder, and pull master cylinder slightly toward engine compartment.
d. On all models, screw in stop light switch until it contacts brake pedal stopper, ensure that brake pedal does not move, then return stop light switch 1/2 to 1 turn and secure by tightening locknut.
e. Connect stop light switch electrical connector and ensure that stop light is not illuminated with brake pedal unpressed, then check reference dimension "B" as shown, should be 0.02-0.04 inch.
f. On 1991 models with shift lock mechanism, check adjustment of shift lock after brake pedal height has been adjusted, refer to "Automatic Transaxles" section and adjust if necessary.
g. On all models, with engine stopped, depress brake pedal two or three times to eliminate vacuum in power brake booster, then press pedal down by hand and confirm that amount of free play, dimension "C," before resistance is felt is within 0.1-0.3 inch on all models except Colt Wagon or 0.4-0.6 inch on Colt Wagon.
h. If free play is less than 0.1 inch, ensure that clearance between stop light switch and brake pedal is within specifications.
i. If free play is greater than 0.4 inch, it is probably due to excessive play between clevis pin and brake pedal arm. Check for excessive clearance and replace defective components as necessary.
j. Start engine, then depress brake pedal with approximately 110 lbs. of force and measure clearance dimension "D" between brake pedal and floorboard. Clearance should be 3.1 inch or more.
k. If clearance is less than 3.1 inch, check for air trapped in brake lines, fluid leaks, excessive brake shoe clearance due to faulty self-adjusters and repair or replace defective components as necessary.