Brake Pedal Assy: Service and Repair

BRAKE PEDAL ASSEMBLY

REMOVAL





1. Remove left lower I/P closeout panel (hush panel).





2. Remove lower HVAC duct push pin and remove duct.





3. Disconnect brake booster push rod from pedal.





4. Disconnect stop lamp switch and cruise brake switch electrical connections, if equipped.





5. Remove stop lamp switch and cruise brake switch, if equipped. Rotate 90° then pull out.





6. Remove accelerator pedal assembly fasteners and move pedal out of the way (L81 shown).





7. Remove intermediate shaft to steering column bolt and move intermediate shaft aside.





8. Remove pedal bracket to I/P beam fasteners.





9. Remove pedal bracket fasteners located under hood around brake booster.

IMPORTANT: The brake pedal cannot be separated from the bracket assembly. The assembly must be serviced as a unit.

10. Remove pedal bracket assembly with pedal.

INSTALLATION
1. Position pedal assembly into vehicle.
2. Position brake booster bracket onto studs and tighten nuts.
Torque:
Brake Booster Bracket Attachment Nuts: 18 Nm (13 ft. lbs.)





3. Install pedal bracket-to-I/P support beam nuts and tighten.
Torque:
Brake Pedal Bracket-to-I/P Support Beam Nuts: 20 Nm (15 ft. lbs.)

IMPORTANT: Use Loctite 242 (R) Threadlocker (or equivalent) on threads of pinch bolt.





4. Install intermediate shaft and pinch bolt.
Torque:
Intermediate Steering Shaft Pinch Bolt: 30 Nm (22 ft. lbs.)





5. Install accelerator pedal.
Torque:
Accelerator Pedal Bracket Nuts: 10 Nm (89 inch lbs.)





6. Connect brake booster push rod to pedal.





7. Install lower HVAC duct and push pin.





8. Install stop lamp switch, and cruise brake switch if equipped.





9. Connect stop lamp and cruise brake switch electrical connector if equipped.





10. Install left lower I/P closeout panel (hush panel) and push pins.