Pedal Positioning System: Service and Repair
PEDALS - ADJUSTABLE
REMOVAL
NOTE: Before proceeding, review all Steering Column and Airbag Warnings and Cautions.
1. Move driver's seat to full rearward position.
2. Disconnect negative battery cable from battery post and isolate.
3. Remove throttle cable from throttle body lever.
Fig. 53 Lower Steering Column Cover And Reinforcement:
4. Remove screws securing lower steering column cover/knee blocker, then remove it.
5. Disconnect parking brake release link at release handle.
6. Compress tabs on sides of data link diagnostic connector and remove it from knee blocker reinforcement plate.
7. Remove screws securing knee blocker reinforcement plate in place, then remove reinforcement plate.
8. Remove hood release from lower left reinforcement.
Fig. 54 Instrument Panel Lower Left Reinforcement:
9. Remove screws securing instrument panel lower left reinforcement in place, then remove reinforcement.
10. Remove brake lamp switch. Discard original switch; it must not be reused.
11. Remove upper and lower steering column shrouds.
12. Disconnect wiring harness connectors (as equipped) from clockspring, multi-function switch, SKIM module, ignition switch and BTSI solenoid.
Fig. 55 Shift Cable At Steering Column:
13. If equipped, disconnect PRNDL cable from shift lever and column bracket.
14. Disconnect shift cable at shift lever mechanism pin.
15. Remove pinch side clip, then remove shift cable from bracket on column.
16. Place front wheels in STRAIGHT-AHEAD position, then secure steering wheel to column in this position using appropriate retaining method.
Fig. 56 PINCH BOLT:
17. Remove pinch bolt securing column coupling to intermediate shaft.
18. Loosen two lower steering column mounting nuts.
19. Remove two upper steering column mounting nuts.
20. Remove steering column assembly.
Fig. 57 Intermediate Shaft Dash Seal And Silencer Shell:
21. Remove dash seal silencer shell over steering column intermediate shaft.
22. Remove two nuts securing brake lamp switch bracket to pedal assembly. Remove bracket.
Fig. 58 Wiring Harness Connection:
23. Disconnect wiring connector connecting vehicle wiring harness connector to pedal wiring harness.
24. Unfasten routing clips retaining vehicle wiring harness to pedal wiring harness.
25. Remove power brake booster input rod from brake pedal pin by performing following:
Fig. 59 Input Rod Brake Pedal Retaining Clip Removal:
a. Position small screwdriver between center tang on retaining clip and brake pedal pin.
b. Rotate screwdriver, moving retaining clip center tang enough to allow it to pass over end of brake pedal pin, then slide retaining clip off brake pedal pin.
c. Discard retaining clip. Retaining clip must not be reused. Install NEW retaining clip when assembling.
d. Slide booster input rod off pedal pin.
Fig. 60 Drive Cable Routing:
26. Disconnect pedal adjuster cable at brake pedal adjustment gear box.
27. Remove pedal adjuster cable from routing loop on steering column bracket, then pull gear box end of cable upward, out of steering column bracket, and down right side of pedals assembly.
Fig. 61 Booster Mounting (Typical):
28. Remove four nuts attaching power brake booster and pedals assembly to dash panel.
29. Remove two upper mounting bolts attaching pedals assembly to steering column support bracket on dash.
30. Disconnect throttle cable retainer at accelerator pedal, then remove cable from pedal.
31. Remove adjustable pedals assembly.
INSTALLATION
1. Install adjustable pedals assembly under instrument panel.
2. Attach throttle cable to accelerator pedal using cable retainer.
3. Install two upper mounting bolts attaching pedals assembly to steering column support bracket on dash panel. Do not fully tighten at this time.
4. Install four nuts attaching pedals assembly and power brake booster to dash panel.
5. Tighten four booster mounting nuts and two upper mounting bolts to 28 Nm (21 ft. lbs.) torque.
6. Route pedal adjuster cable up and over right side of pedals assembly and steering column bracket, then down through hole in steering column bracket as shown. Attach end of cable to gear box.
7. Place adjuster cable through loop on right side of steering column bracket as shown.
8. Install booster input rod onto brake pedal pin and install a NEW retaining clip.
9. Connect wiring connector connecting vehicle wiring harness to pedal wiring harness.
10. Connect routing clips retaining vehicle wiring harness to pedal wiring harness.
11. Install brake lamp switch bracket on pedals assembly Tighten mounting nuts to 6 Nm (50 inch lbs.) torque.
12. Install dash seal silencer shell over steering column intermediate shaft and fasten in place.
13. Install steering column onto lower mounting studs with nuts started, then install column onto upper mounting studs and install two upper mounting nuts. Tighten upper, then lower mounting nuts to 12 Nm (105 inch lbs.) torque.
14. Install column shaft coupling onto intermediate shaft and install pinch bolt. Make sure rounded side of intermediate shaft is matched to the curvature of the coupling. Tighten pinch bolt to 28 Nm (250 inch lbs.) torque.
15. Remove retainer holding steering wheel in place on steering column.
16. Attach shift cable to bracket on column.
17. Connect shift cable end to shift lever mechanism pin.
18. If equipped, connect PRNDL cable to end of shift lever mechanism pin and column bracket.
19. Connect column wiring harness connectors (as equipped) to SKIM, BTSI solenoid, ignition switch, multi-function switch, and clockspring.
20. Install lower and upper steering column shrouds.
CAUTION: Do not reuse the original brake lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted.
21. Install and adjust NEW brake lamp switch.
22. Install instrument panel lower left reinforcement.
23. Attach hood release to lower left reinforcement.
24. Install knee blocker reinforcement plate.
25. Connect parking brake release link to release handle.
26. Install data link diagnostic connector to mounting hole in reinforcement plate.
27. Install lower steering column cover/knee blocker.
28. Install throttle cable onto throttle body lever.
NOTE: When reconnecting the battery on a vehicle that has had the airbag module removed, the following procedure should be used.
29. Reconnect ground cable to negative post of battery following special Diagnosis And Testing procedure. Testing and Inspection
30. Test operation of adjustable pedals and all functions that are steering column operated. If applicable, reset radio and clock.
31. Road test the vehicle to ensure proper operation of steering and brake systems.