Brake Pedal Assy: Service and Repair

BRAKE PEDAL SUPPORT SUB-ASSEMBLY
OVERHAUL
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3. REMOVE SWITCH & VOLUME CASE
4. REMOVE STEERING WHEEL COVER LOWER NO.2
5. REMOVE HORN BUTTON ASSEMBLY
6. REMOVE STEERING WHEEL ASSEMBLY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
7. REMOVE STEERING COLUMN COVER
8. REMOVE SPIRAL CABLE SUB-ASSEMBLY
9. REMOVE TURN SIGNAL SWITCH ASSEMBLY
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
11. REMOVE INSTRUMENT CLUSTER FINISH PANEL END
12. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1
13. REMOVE COIN BOX ASSEMBLY
14. REMOVE OUTER MIRROR SWITCH ASSEMBLY
15. REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
16. REMOVE INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
17. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2
18. REMOVE INSTRUMENT CLUSTER FINISH PANEL
19. REMOVE COMBINATION METER ASSEMBLY
20. REMOVE PUSH ROD PIN





a. Disconnect the stop lamp switch connector and brake pedal load sensing switch connector.





b. Remove the brake pedal return spring.





c. Remove the clip and push rod pin.
21. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY





a. Remove the bolt.





b. Remove the brace, bolt and nut.
c. Remove the brake pedal support sub-assembly and the 3 nuts.





22. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a. Remove the nut, the brake pedal shaft washer and the brake pedal sub-assembly from the brake pedal support sub-assembly.





23. REMOVE BRAKE PEDAL PAD
a. Remove the brake pedal pad from the brake pedal sub-assembly.





24. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Loosen the lock nut and remove the stop lamp switch assembly.
b. Remove the stop lamp switch cushion.





25. REMOVE BRAKE PEDAL BUSH
a. Remove the 2 brake pedal bushes from the brake pedal sub-assembly.
26. REMOVE BRAKE PEDAL SHAFT COLLAR
a. Remove the brake pedal shaft collar from the brake pedal sub-assembly.





27. INSTALL BRAKE PEDAL SHAFT COLLAR
a. Apply lithium soap base glycol grease to the ends and sides of the brake pedal shaft collar.
b. Install the brake pedal shaft collar to the brake pedal sub-assembly.
28. INSTALL BRAKE PEDAL BUSH
a. Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushes.
b. Install the new brake pedal bushes to the brake pedal sub-assembly.





29. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Install the stop lamp switch assembly with the stop lamp switch lock nut.
Torque: 17 Nm (173 kgf-cm, 12 ft. lbs.)

HINT: After adjusting the brake pedal height, torque the lock nut.

b. Install the stop lamp switch cushion.
30. INSTALL BRAKE PEDAL PAD
a. Install the brake pedal pad to the brake pedal sub-assembly.





31. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a. Install the brake pedal sub-assembly with the brake pedal shaft washer and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
32. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY





a. Place the brake pedal support sub-assembly on the vehicle and temporarily tighten the bolt.





b. Place the brace on the vehicle and temporarily tighten the bolt and nut.
c. Temporarily tighten the 3 nuts.





d. Tighten the bolt.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





e. Tighten the bolt.
Torque: 20 Nm (204 kgf-cm, 14 ft. lbs.)
Tighten the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
33. INSTALL PUSH ROD PIN





a. Apply lithium soap base glycol grease to the push rod pin.
b. Place the master cylinder push rod clevis, insert the push rod pin and install the clip.





c. Install the brake pedal return spring.





d. Connect the stop lamp switch connector and brake pedal load sensing switch connector.
34. CHECK AND ADJUST BRAKE PEDAL HEIGHT
35. CHECK PEDAL FREE PLAY
36. CHECK PEDAL RESERVE DISTANCE
37. INSTALL COMBINATION METER ASSEMBLY
38. INSTALL INSTRUMENT CLUSTER FINISH PANEL
39. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2
40. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
41. INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY NO.1
42. INSTALL OUTER MIRROR SWITCH ASSEMBLY
43. INSTALL COIN BOX ASSEMBLY
44. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.1
45. INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
46. INSTALL INSTRUMENT CLUSTER FINISH PANEL END
47. INSTALL TURN SIGNAL SWITCH ASSEMBLY
48. INSTALL SPIRAL CABLE SUB-ASSEMBLY
49. INSTALL STEERING COLUMN COVER
50. INSTALL STEERING WHEEL ASSEMBLY
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
51. INSTALL HORN BUTTON ASSEMBLY
52. INSTALL STEERING WHEEL COVER LOWER NO.2
53. INSTALL SWITCH &VOLUME CASE
54. CONNECT BATTERY NEGATIVE TERMINAL
55. INSPECT SRS WARNING LIGHT
56. PERFORM INITIALIZATION