Brake Pedal Assy: Service and Repair

Brake, Accelerator, and Clutch Pedal Replacement

Special Tools

* DT-6202-A - Pliers

* DT-6202-B - Pliers

* DT-6202-20 - Adapter to DT-6202-A

* DT-50894 - Remover

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

1. Remove the battery. Refer to Battery Replacement Removal and Replacement.

2. Remove the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.





Note: Do NOT disconnect engine coolant hoses.

3. Remove the radiator surge tank clip (2).

4. Remove the radiator surge tank (1).
Position the radiator surge tank (1) aside.




5. Remove the BPMV bracket bolts (1).




6. Remove the brake booster bolts (1).





Note:

* Do NOT open hydraulic brake system.

* Second mechanic required.

7. Pull the brake booster and the BPMV assembly forward in order to get access to the brake pedal bracket nuts (1).

8. Remove the brake pedal bracket nuts (1).

9. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side Instrument Panel Lower Trim Panel Replacement - Left Side.

10. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement Steering Column Upper Trim Cover Replacement.

11. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement Steering Column Lower Trim Cover Replacement.

12. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.

13. Remove the steering column. Refer to Steering Column Replacement Steering Column Replacement.




14. Disconnect the brake pedal pushrod (1) from the brake pedal. Apply the brake pedal a bit to facilitate removal.




15. Replace click fit connector (1) between booster pushrod and brake pedal with new part.




16. If equipped, disconnect the clutch master cylinder push rod from the clutch pedal (3), using either the DT-6202-A - pliers (1) and the DT-6202-20 - adapters in conjunction with the DT-50894 - remover (2), or the DT-6202-B - pliers (1) in conjunction with the DT-50894 - remover (2).




17. Remove the clutch master cylinder nuts (1) from the pedal bracket, if equipped.




18. Remove the brake pedal bracket bolt (1) from the tie bar.

19. Separate wiring harness from pedal bracket.

20. Disconnect electrical connectors.




21. Carefully bend the fuse box bracket (1) to the side to allow space for pedal assembly removal.

22. Remove brake and accelerator and clutch pedal assembly from vehicle.

23. Transfer component parts as needed.

Installation Procedure




1. Install the brake and accelerator and clutch pedal assembly to the vehicle.

2. Carefully bend the fuse box bracket (1) back in position

3. Install wiring harness to brake pedal bracket.

4. Connect electrical connectors.

Caution: Refer to Fastener Caution Fastener Caution.

5. Install brake pedal bracket bolts and tighten to 20 Nm (15 lb ft).

6. Connect clutch master cylinder push rod (1) to the clutch pedal, if equipped. The retaining clip must engage audibly.




7. Install the clutch master cylinder nuts (1) to the pedal bracket, if equipped and tighten to 18 Nm (13 lb ft).




8. Connect the brake pedal pushrod (1) to the brake pedal.

9. Install the steering column. Refer to Steering Column Replacement Steering Column Replacement.

10. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.

11. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement Steering Column Lower Trim Cover Replacement.

12. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement Steering Column Upper Trim Cover Replacement.

13. Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side Instrument Panel Lower Trim Panel Replacement - Left Side.





Note:

* Do NOT open hydraulic brake system.

* Second mechanic required.

14. Pull the brake booster and the BPMV assembly forward in order to gain access to the brake pedal bracket nuts (1).

15. Install the pedal bracket nuts (1) and tighten to 20 Nm (15 lb ft).




16. Install the brake booster bolts (1) and tighten to 19 Nm (14 lb ft).




17. Install the BPMV bracket bolts (1) and tighten to 20 Nm (15 lb ft).





Note: DO NOT disconnect engine coolant hoses.

18. Install the radiator surge tank (1).

19. Install the radiator surge tank clip (2).

20. Install the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.

21. Install the battery. Refer to Battery Replacement Removal and Replacement.

22. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .