Brake Pedal Assy: Service and Repair

NOTE: Manual transmission pedal assembly and procedure shown, automatic transmission similar.

Component Notes And Information

WARNING: Brake pedal travel must never be restricted by carpets or floor mats

NOTE: Grease contact points with white grease, Part No. G052 142 A2 or equivalent.

1 Return Spring
- Fit U shaped end into pedal bracket
- Connect other end in sleeve of clevis
2 Pedal Bracket
- Do not remove to remove clutch and brake pedals
3 Return Hose
- From brake fluid reservoir to clutch master cylinder
4 Locking Clip
- Always replace
- Install on pedal bracket shaft
5 Over Center Spring
- Do not grease
- Only grease contact points on pedal and/or pedal bracket
- removing and installing, refer to Fig. 2, below
6 Locking Clip
- Always replace
- Install on pedal bracket shaft
7 Locking Clip
- Always replace
- Install on pedal bracket shaft
8 Pin
- Install in clevis and clutch pedal
9 Clutch Pedal
- Position set by adjustment of clevis
- Attach to pedal bracket shaft
- Can be removed and installed without removing bracket
- Supplied as a replacement part with an injection moulded bushing (bushing is not replaceable)
10 Self Locking Nut
- Always replace
- Tighten to: 25 Nm (18 ft lbs)
- Mount pedal bracket to bulkhead or intermediate mount
11 Brake Booster
- If necessary, replace only as a complete assembly
12 Lock Nut
- Tighten after adjusting clevis
13 Grommet
- Install in clevis
14 Pin
- Install in clevis and brake pedal
15 Locking clip
- Always replace
- Attach to pin
16 Clevis For Brake Booster
- Adjustment, refer to Adjusting Clevis. Adjustments
17 Locking Clip
- Always replace
- Install on pedal bracket shaft
18 Brake Pedal
- Mount on pedal bracket shaft
- Can be removed and installed without removing bracket
- Supplied as a replacement part with an injection moulded bushing (bushing is not replaceable)
19 Self Locking Nut
- Always replace
- Tighten to: 25 Nm (18 ft lbs)
20 Brake Light Switch
- Adjust as follows:
Deoress pedal
Press brake light switch in fully
pull brake pedal back by hand to stop
21 Clip
- Press into pedal cluster fully
22 Socket Head Bolt
- Tighten to: 20 Nm (15 ft lbs)
- Mounts clutch master cylinder to bracket
23 Clutch Master Cylinder
- Replace if leaking
- Adjusting clevis, refer to Fig. 1, below

Procedures





Fig. 1 Adjusting Clutch Master Cylinder Clevis
- Dimension a = 109.5 ± 0.5 mm (4.31 ± 0.02 inch)
- To adjust turn clevis as necessary

NOTE:
^ While measuring, the clevis must be aligned at a right angle to the surface of the clutch master cylinder.
^ If the clutch pedal does not return to rest position by itself even though the clevis is correctly adjusted:
There may be air in the clutch hydraulic system.
There may be too much friction in the pedal bushing.





Fig. 2 Removing And Installing Over Center Spring
- Remove locking clip from pin.
- Install spring retainer, tool No. 3117, or equivalent, as shown, then depress clutch pedal and remove over center spring from pedal bracket or clutch pedal.

NOTE: the illustration above shows the spring retainer with the pedal bracket removed.