Adjustable Accelerator Pedal Bracket Assembly Replacement

ADJUSTABLE ACCELERATOR PEDAL BRACKET ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE
1. Disconnect the adjustable pedal motor electrical connector.

IMPORTANT: Ensure the brake pedal assembly is adjusted to the lowest position farthest from the drivers seat prior to removal of the accelerator assembly. Failure to do so could result in incorrect step-over height between the brake and accelerator pedals and improper function of the adjustable pedal system.

2. Remove the accelerator pedal assembly.
3. Remove the accelerator pedal bracket nuts.
4. Remove the accelerator pedal harness from the accelerator pedal bracket.
5. Remove the adjustable pedal drive cable from the accelerator pedal actuator using the following procedure:
1. Twist the cable housing counterclockwise.
2. Using needle nose pliers or equivalent, compress the secondary locking tabs located below the twist and lock tabs and remove the cable from the pedal actuator.
6. Remove the accelerator mounting nuts from the accelerator bracket.
7. Remove the accelerator actuator lower pivot pin retaining push nut.
8. Remove the accelerator actuator lower pivot pin.
9. Remove the accelerator actuator mounting screws.
10. Remove the accelerator actuator.

INSTALLATION PROCEDURE
1. Install the accelerator actuator to the accelerator pedal bracket.

IMPORTANT: Accurate measurement and adjustment of the following steps is critical to ensure the proper step-over distance between the brake and accelerator pedals.

2. Install the accelerator actuator mounting screws to the accelerator pedal bracket.

Tighten the screws to 2.5 N.m (22 lb in).

NOTE: Refer to Fastener Notice.

3. Install the accelerator actuator lower pivot pin.
4. Install the accelerator actuator lower pivot pin retaining push nut.In order to allow proper actuation of the adjustable bracket, the push nut must allow some free play of the pivot pin. The distance between the bracket side wall and the push nut should be 1.7 mm.
5. Install the adjustable drive cable into the accelerator actuator.
1. Install the adjustable cable into the accelerator pedal assembly until secured by the secondary locking tabs.
2. Install and twist the cable housing to secure to the accelerator pedal assembly.
6. Install the accelerator pedal electrical harness. Ensure the harness routes properly through the backside of the bracket without pinching.
7. Install the accelerator bracket mounting nuts.

Tighten the nuts to 9 N.m (80 lb in).

8. Adjust the accelerator pedal mounting bracket using the following procedure:
1. Remove the screws from the cable housing at the top of the adjustable pedal motor.
2. Twist the cable housing to unlock the cable from the motor.
3. Remove the cable from the adjustable pedal motor.
4. Attach a drill motor or equivalent to the adjustable pedal cable.
5. Spin the cable until there is a distance of 6.14 mm between the arrows on the inboard side of the adjustable pedal bracket.
9. Install the accelerator pedal assembly.
10. Connect the adjustable pedal motor electrical connector.
11. Verify operation of the adjustable pedals.