Brake Pedal Assy: Service and Repair

REMOVE

Ground Cable Attachment At Strut Tower:

1. Remove the remote ground cable from the ground stud located on the left strut tower.

NOTE: Step 2 below is to be done to prevent the accidental grounding of the remote ground cable.

Correctly Isolated Remote Ground Cable:

2. Correctly isolate remote ground by installing the ground cable insulator on the strut tower ground stud as shown.

Stop Lamp Switch:

3. Remove the stop lamp switch from the brake pedal bracket. Stop lamp switch is removed using the following procedure. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise direction approximately 30°.

Brake Pedal Retaining Clip:

4. Remove the retaining clip from the brake pedal pin using following procedure. Position a small screwdriver between the center tang on the retaining clip and the brake pedal pin. Rotate blade of screwdriver enough so center tang on retaining clip can pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin.
5. Remove the nut from the brake pedal pivot pin.
6. Remove bake pedal pivot pin from the brake pedal and pedal mounting bracket.
7. Remove brake pedal from mounting bracket.

INSTALL
1. Lubricate the brake pedal pivot pin and brake pedal bushings using Mopar Lubriplate or an equivalent.
2. Install the brake pedal in the pedal bracket. Align the pivot pin hole in brake pedal with pivot pin holes in pedal bracket.
3. Install nut on brake pedal pivot pin. Tighten pivot pin attaching nut to a torque of 34 Nm (25 ft. lbs.).
4. Install the vacuum booster push rod on the brake pedal pin.

CAUTION: When installing the retaining clip on the brake pedal pin a NEW retaining clip must be used to ensure the retention of the vacuum booster push rod.

5. Install a NEW retaining clip on the brake pedal pin.

Master Cylinder Fluid Level Sensor:

6. Using Mopar Lubriplate or an equivalent, lightly lubricate the surface of the brake pedal striker which the plunger of the stop lamp switch contacts.

NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully extended position using the procedure in Step 7.

7. Hold stop lamp switch firmly in one hand. Using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position.
8. Connect the wiring harness connector to the stop lamp switch.
9. Install the stop lamp switch in the brake pedal bracket. Stop lamp switch is installed using the following procedure. Depress the brake pedal as far down as possible. Then while holding brake pedal down, align index key on switch with slot in square hole of mounting bracket. When switch is fully installed in bracket, rotate stop lamp switch in a clockwise direction approximately 30 degrees.

CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch. If to much force is used, damage to the stop lamp switch or striker can result.

10. Gently pull back on the brake pedal until it stops moving. This will cause the switch plunger to ratchet back to its correct position.
11. Install the silencer panel/air duct.
12. Connect the remote ground cable for the battery on the ground post located on left shock tower.