Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
2. Remove the instrument cluster. Refer to Instrument Cluster Replacement (Instrument Cluster Replacement).




3. Remove the brake pedal return spring (1) from the brake pedal support.




4. Remove the clip (3) from the push rod clevis pin (2).
Discard the clip.
5. Remove the push rod clevis pin from the push rod clevis (1).
6. Separate the push rod clevis from the brake pedal.




7. Disconnect the stop lamp switch connector (1).




8. Turn the stop lamp switch (1) counter clockwise and remove the stop lamp switch.
9. Remove the stop lamp switch mounting adjuster from the brake pedal support.




10. Remove the bolt (1) and separate the brake pedal support from the instrument panel reinforcement.




11. Disengage the 2 clamps (1) from the brake pedal support.




12. Remove the 4 nuts (1, 2, 3, 4) and the brake pedal support from the vehicle.




13. Remove the nut (1) from the brake pedal support.




14. Remove the shaft bolt (2) and the nut (1).




15. Remove the pedal (7) from the support (13).
16. Remove the 2 bushings (5) from the pedal.
Discard the bushings.
17. Remove the cover (6) from the pedal.

Installation Procedure




1. Install the cover (6) to the brake pedal (7).
2. Apply lithium soap base glycol grease to 2 NEW bushings (5).
3. Install the bushings to the pedal.
4. Install the pedal to the support (13).





Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the nut (1) to the shaft bolt and tighten to 37 Nm (27 lb ft).




6. Install the nut (1) to the brake pedal support.




7. Install the support to the vehicle with the 4 nuts (1, 2, 3, 4) and tighten to 13 Nm (115 lb in).




8. Engage the 2 clamps (1) to the brake pedal support.




9. Install the brake pedal support to the instrument panel reinforcement with the bolt (1) and tighten to 24 Nm (18 lb ft).
10. Install the stop lamp switch mounting adjuster to the brake pedal support.





Note: While installing the stop lamp switch, support the pedal from behind in order to prevent pushing the pedal in.

11. Install the stop lamp switch (1) until the rod hits the cushion.
12. Turn the stop lamp switch 90 degrees clockwise.
13. Adjust the stop lamp clearance. Refer to Stop Lamp Switch Adjustment (Adjustments).




14. Connect the stoplamp switch connector (1).




15. Apply lithium soap base glycol grease to the push rod clevis pin (2) and to the clevis pin hole in the pedal.
16. Install the push rod clevis pin in order to retain the push rod clevis (1) to the pedal.
17. Install a NEW clip (3) in order to retain the clevis pin to the pedal.




18. Install the brake pedal return spring (1) between the brake pedal support and the push rod clevis.
19. Measure the brake pedal travel. Adjust if necessary. Refer to Brake Pedal Travel Measurement and Inspection (Brake Pedal Travel Measurement and Inspection).
20. Install the instrument cluster. Refer to Instrument Cluster Replacement (Instrument Cluster Replacement).
21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).