BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/o Vacuum Brake Booster): REMOVAL; 2024 - 2025 MY RAV4 RAV4 HV [10/2023

Last Modified: 05-08-2025	6.11:8.1.0	Doc ID: RM100000002FR6D
Model Year Start: 2024	Model: RAV4	Prod Date Range: [10/2023 - ]
Title: BRAKE SYSTEM (OTHER): BRAKE PEDAL (w/o Vacuum Brake Booster): REMOVAL; 2024 - 2025 MY RAV4 RAV4 HV [10/2023 - ]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during brake pedal support assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced (for HV Model)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
1: When performing learning using the GTS. Click here 2: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation.
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane control system
		Parking support brake system (for HV model)*1
		Pre-collision system
	Reset back door close position	Power back door system
	Power back door initialization	Power door lock control system
Brake pedal*2	Perform "Reset Memory" Perform "Calibration"	DTCs are stored ABS warning light illuminates Brake system warning light (yellow indicator) illuminates Slip indicator light illuminates Brake control disabled or malfunctions (brake drag, etc.)

NOTICE:

After the ignition switch is turned off, the audio and visual system records various types of memory and settings. As a result, after turning the ignition switch off, make sure to wait at least 2 minutes before disconnecting the cable from the negative (-) auxiliary battery terminal.
When the cable is disconnected from the negative (-) auxiliary battery terminal and the security lock setting has been enabled, multi-display operations will be disabled upon next startup unless the password is entered. Be sure to check the security lock setting before disconnecting the cable from the negative (-) auxiliary battery terminal.
While the auxiliary battery is connected, even if the power switch is off, the brake control system activates when the brake pedal is depressed or any door courtesy switch turns on. Therefore, when servicing the brake system components, do not operate the brake pedal or open/close the doors while the auxiliary battery is connected.

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read precaution thoroughly before servicing.

Click here

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

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2. REMOVE LOWER NO. 1 INSTRUMENT PANEL AIRBAG ASSEMBLY

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3. REMOVE NO. 1 AIR DUCT (for TMC Made)

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4. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for TMMC Made)

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5. REMOVE BRAKE PEDAL STROKE SENSOR ASSEMBLY

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6. REMOVE STOP LIGHT SWITCH ASSEMBLY

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7. REMOVE ENGINE ROOM MAIN WIRE

(a) Disengage the 2 clamps to separate the engine room main wire from the brake pedal support assembly.

8. REMOVE BRAKE PEDAL RETURN SPRING

(a) Remove the brake pedal return spring from the brake pedal support assembly.

9. REMOVE PUSH ROD PIN

(a) Remove the clip and push rod pin to separate the master cylinder push rod clevis from the brake pedal support assembly.

10. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY

(a) Remove the 2 clips.

(b) Remove the bolt and 4 nuts and push the brake booster with master cylinder assembly toward the engine compartment.

NOTICE:

Do not apply excessive force to the brake lines.
Do not apply excessive force to the wire harness.

(c) Remove the brake pedal support assembly while avoiding the stud bolts of the brake booster with master cylinder assembly and brake booster support base.

NOTICE:

Be careful not to deform the bracket of the instrument panel reinforcement assembly.

11. REMOVE STOP LIGHT SWITCH MOUNTING ADJUSTER

(a) Disengage the 2 claws and remove the stop light switch mounting adjuster.

12. REMOVE BRAKE PEDAL PAD

(a) Remove the brake pedal pad from the brake pedal support assembly.