Brake Pedal Assy: Service and Repair

Brake Pedal and Bracket

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










Removal and Installation

All vehicles

1. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch and speed control deactivator switch. These switches must be removed with the brake pedal in the at-rest position. Switch plungers must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

Remove the stoplamp switch.

2. Remove the brake pedal speed control deactivation switch.

3. Remove the redundant self-locking pin cover and the self-locking pin.

4. Remove the booster rod pin from the brake pedal.

Manual transmission vehicles

5. NOTICE: The clutch pedal must be connected to the clutch master cylinder actuation rod and in the at-rest position before removing or installing the speed control deactivator switch. Failure to follow this instruction will damage the switch.

Remove the clutch pedal speed control deactivator switch.

6. Disconnect the Clutch Pedal Position (CPP) switch electrical connector.

7. Disconnect the clutch pedal low pressure hydraulic hose from the master cylinder reservoir.

8. NOTE: The clutch master cylinder is self-bleeding. Pump the clutch pedal until all the air is forced back into the brake master cylinder reservoir.

Remove the hairpin clip and disconnect the clutch pedal high pressure hydraulic hose from the clutch master cylinder.

- Install the hairpin clip into the clutch master cylinder.

All vehicles

9. Remove the 4 brake booster nuts.
- To install, tighten to 25 Nm (18 lb-ft).

10. Remove the top 2 bolts from the brake pedal bracket assembly.
- To install, tighten to 25 Nm (18 lb-ft).

11. Remove the brake pedal bracket assembly from the vehicle.

12. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp switch or the speed control deactivator switch. These switches must be installed with the booster push rod attached to the brake pedal and with the brake pedal in the at-rest position. Installing these switches with the brake pedal in any other position will result in incorrect adjustment and may damage the switches.

To install, reverse the removal procedure.