Binding brake pedal linkage

First post here so be gentle.
I have a 2003 toyota tacoma prerunner 6cylinder, I have been chasing a stiff brake pedal for a bit. I have replaced the booster and the master cylinder before finally taking it to a local shop. While it was there they replaced the booster again and went through the brakes and found no other issues on the brakes themselves. I had them go ahead and do the water pump and timing belts as the reuck was pushing 200,000 miles and I wasn't sure of the previous history. The mechanic took it for a test drive and said the pedal was still binding some but you could push through it and I needed a discontinued part from Toyota# 4711235010 lever brake pedal. I did some looking and was able to find a brand new one so they put it in and I still have the same issue. They said it was fixed but it still isn't right sometimes it hangs up and I am able to push through it and feel the booster working. I was messing with it today and noticed the part they installed is still moving side to side when you press the pedal and sometimes it moves freely and sometimes it binds up depending on the angle of the part they installed. I have attached a photo showing the part I'm talking about binding along with the parts diagram of that area. I have ordered the parts I believe are wore out or just straight missing judging by the lean of the lever after pushing it a few times. Can somebody with a similar brake set up take photo so I can compare to mine? The diagram is what I am going by and it looks like I am missing a bushing in the bottom of the lever along with one on the top of the lever. If I look at the diagram correctly the bottom hole should have a bushing on each side with a spacer in between, I only see the white bushing on the left side of the bottom hole. The lever part that was replaced is referenced as 47112 in the diagram

 

Well I got my bushings and parts in the other day and using the diagram above I was able to figure out what had happened. The mechanic did not install the bushing in the top of the lever arm so it was sliding over and causing the main bind. I added that and replaced the bushings on the bottom of the lever and it doesn't bind I can actually feel the booster moving, before it was almost wedging the truck would still stop but it was like the booster wasn't there. I still have a slightly stiff feel when I first press the pedal but is pushes right through. I think that's just the way it feels, I had already replaced the master cylinder and bled the lines and put in new brake fluid efore the booster was replaced.

 

Was just going thru this issue on my 03. #47112 has that binding/diag play when loaded sometimes that brought the inconsistent pedal travel.

Some washers for this and some lube on the squeaky clutch spring and ill be rockin

Thanks for documenting griff!

 

I had forgotten about this it worked well for about a year and then I had to take it back as the booster they had installed went bad. That makes like the third booster on the truck. The original one the one I put on that was defective and the one they put on that was also defective. So far so good with the new one.

 

Hey, where’d you order the Toyota #4711235010 brake lever from? I’ve been trying to find it i’m having a similar issue but unable to find it anywhere.

 

Junkyard unfortunately. I literally spent several days trying to find one brand new. I couldn't tell you how many I ordered only to find out later they didn't have them. I think I got lucky and literally found the last one in the US. I called every toyota dealer I could find and finally a place in FL told me there where 2 left in the inventory that he could see across the network. I surely ordered it once he verified he could get it to me and that was almost 2 years ago, so to be sure the other one is gone by now. Are you sure it's you lever that's bad and not the bushing. I talked to my local backyard mechanic awhile back about the lever I didn't know he was there until after I went through my ordeal. He said if my lever had actually been bad he could have sleeved it or the equivalent, basically build it up with weld and then ream it to size.

 

Thanks for the info. I’ve tried the junkyard before but haven’t been able to get a tacoma around my years for parts. I’m pretty sure it’s that cause when pushing the pedal it was constantly hitting and now it’s had indents. I’ve placed the booster twice. Currently running the truck with the brake pedal attached directly to the booster without the lever installed. That was the only way for my to be able to brake otherwise the brake pedal was stiff and wouldn’t budge. Right now the braking pressure is very loose but able to break.

 

That not good, I know with mine I had a defective new booster and then the one the shop installed after I gave up was defective to. Sorry on the lever it was a struggle to find the one I found.