Brake Pedal Assy: Service and Repair
PEDAL TORQUE SHAFT - RHDREMOVAL
1. Remove the instrument panel.
2. Remove the HVAC housing.
3. Remove the retaining clip at the torque shaft end of the brake pedal-to-torque shaft link. Remove the link from the torque shaft. Discard the retaining clip. It is not to be reused. Replace with a new clip when reassembled.
4. Locate the booster input rod-to-brake pedal torque shaft connection and remove the retaining clip. Discard the retaining clip. It is not to be reused. Replace with a new clip when reassembled.
5. Remove the four (4) brake booster retaining nuts from inside the passenger compartment.
6. Remove the retaining nut from the brake booster bracket located above the booster in the engine compartment.
7. Remove the power brake booster bracket.
8. Rotate the pedal torque shaft and remove it out the left side of the vehicle.
INSTALLATION
1. Lubricate both ends of the torque shaft with MS-4517 Lubricant or equivalent and install the torque shaft from the left side reversing the removal procedure.
2. Install the brake booster bracket on the left end of the shaft.
3. Install the retaining nut for the brake booster bracket in the engine compartment. Tighten the mounting nut to a torque of 29 Nm (250 in. lbs.).
4. Install the four brake booster retaining nuts inside the passenger compartment. Tighten the mounting nuts to a torque of 29 Nm (250 in. lbs.).
5. Using lubriplate, or equivalent, coat the surface of the brake pedal torque shaft pin where it contacts the booster input rod. Also coat the surface of the brake pedal torque shaft pin where it contacts the brake pedal link.
CAUTION: When installing the power brake booster input rod on the brake pedal torque shaft pin, do not reuse the old retaining clip.
6. Install booster input rod on brake pedal torque shaft pin and install a NEW retaining clip.
CAUTION: When installing the brake pedal link on the brake pedal torque shaft pin, do not reuse the old retaining clip.
7. Connect the brake pedal link to the torque shaft. Install a NEW retaining clip at the torque shaft end of the brake pedal-to-torque shaft link.
8. Install the HVAC housing.
9. Install the instrument panel.
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.
10. Remove and replace the brake lamp switch with a NEW switch.
11. Road test vehicle to ensure proper operation of the brakes.