Brake Pedal Assy: Service and Repair

OVERHAUL

HINT: COMPONENTS: See Diagrams; Exploded Views and Instrument Panel, Gauges and Warning Indicators.

1. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
2. REMOVE INSTRUMENT PANEL REINFORCEMENT
3. REMOVE BRAKE PEDAL RETURN SPRING
4. REMOVE PUSH ROD PIN
a. Remove the clip and push rod pin.
5. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY
a. Disconnect the stop lamp switch connector.
b. Remove the bolt, 4 nuts and brake pedal support assembly.
6. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Loosen the lock nut and remove the stop lamp switch.
7. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a. Remove the nut, bolt and brake pedal sub-assembly from brake pedal support assembly.
8. REMOVE BRAKE PEDAL PAD
9. REMOVE BRAKE PEDAL BUSH
a. Remove the 2 brake pedal bushes from brake pedal.
10. REMOVE STOP LAMP SWITCH CUSHION
11. INSTALL STOP LAMP SWITCH CUSHION
12. INSTALL BRAKE PEDAL BUSH
a. Install the new 2 brake pedal bushes to brake pedal.

HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows.

13. INSTALL BRAKE PEDAL PAD
14. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a. Install the brake pedal sub-assembly with the bolt and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
15. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Install the stop lamp switch with the lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
16. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
a. Install the brake pedal support assembly with the bolt and 4 nuts.
Torque:
Bolt: 20 Nm (204 kgf-cm, 15 ft. lbs.)
Nut: 13 Nm (130 kgf-cm, 9 ft. lbs.)
17. INSTALL PUSH ROD PIN
a. Install the push rod pin and clip.

HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows.

18. INSTALL BRAKE PEDAL RETURN SPRING
19. INSTALL INSTRUMENT PANEL REINFORCEMENT
20. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY
21. CHECK AND ADJUST BRAKE PEDAL HEIGHT
22. CHECK PEDAL FREE PLAY
23. CHECK PEDAL RESERVE DISTANCE