Brake Pedal Assy: Service and Repair
REMOVAL
1. Remove the remote ground cable from the ground stud located on the left strut tower. Correctly isolate remote ground by installing the ground cable insulator on the strut tower ground stud as shown.
2. Remove the two screw securing the bottom of the knee bolster below the steering column in place.
3. Remove the heat distribution duct.
4. Remove the brake lamp switch from its bracket. The brake lamp switch is removed by depressing and holding the brake pedal while rotating brake lamp switch in a counter-clockwise direction approximately 30°.
5. Pull the switch rearward and remove it from its mounting bracket.
6. Remove the retaining clip from the brake pedal pin securing the power booster to the pedal 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.
7. Remove the booster input rod from the brake pedal pin.
8. Remove the nut from the brake pedal pivot shaft. The pivot shaft has a flat on it to hold while the nut is removed.
9. Remove the brake pedal pivot shaft from the brake pedal and pedal mounting bracket.
10. Remove the brake pedal with bushings from mounting bracket.
NOTE: The bushings can be easily removed from the pedal by pulling them straight out each side.
INSTALL
1. Make sure the pedal has a properly installed bushing on each side of the pedal.
2. Lubricate the brake pedal pivot shaft and brake pedal bushings using Mopar Lubriplate or an equivalent.
3. Install the brake pedal in the pedal bracket. Align the hole in brake pedal with the pivot shaft holes in the pedal bracket.
4. Install the brake pedal shaft.
5. Install the nut on the end of the brake pedal pivot shaft. Tighten the nut to a torque of 34 Nm (25 ft. lbs.).
6. Install the power brake booster input 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.
7. Install a new retaining clip on the brake pedal pin.
8. Using Mopar Lubriplate or an equivalent, lightly lubricate the surface of the brake pedal striker where the plunger of the brake lamp switch contacts it.
NOTE: Prior to installing the brake lamp switch into its bracket, the plunger must be moved to its fully extended position using the procedure in Step 9.
9. 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.
10. Install the brake lamp switch in the brake pedal bracket. Install it using the following procedure. Depress the brake pedal as far down as possible. Then while holding brake pedal down, align the index key on switch with slot in square hole of mounting bracket. When switch is fully installed into the bracket, rotate stop lamp switch in a clockwise direction approximately 30 ° until it is aligned straight up and down.
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the brake lamp switch. If to much force is used, damage to the brake lamp switch or striker can result.
11. Gently release/pull back the brake pedal until it stops moving. This will cause the switch plunger to ratchet back to its correctly adjusted position.
12. Install the heat distribution duct.
13. Install the two screws securing the bottom of the knee bolster below the steering column in place.
14. Connect the remote ground cable for the battery on the ground post located on left shock tower.