Brake Pedal Assy: Service and Repair

Brake pedal, LHD
To remove
1. Move the seat all the way back.
2. Remove the ABS, TCS or ESP unit.





3. Disconnect the electrical switch connection and remove the ABS, TCS or ESP unit bracket.
4. Unplug the engine cable harness electrical connection and remove the holder from the bulkhead.





5. Remove the retaining nuts from the brake servo bracket/pedal assembly.
6. Remove the lower dashboard panel.





7. Remove the stepping motor.
8. Fasten the steering wheel to the dashboard with adhesive tape.
9. Loosen the steering shaft UJ from the steering gear without separating the splines.





10. Remove the bolts securing the pedal bracket to the steering column assembly.
11. Unplug the pedal switch connections.
12. Unhook the return spring from the pedal.
13. Remove the clip and pull out the pin.
14. Lift out the pedal assembly.

To fit





1. Fit the pedal assembly loosely to the steering column assembly and place the foam rubber damper in position between the pedal assemblies.
2. Tighten the pedal assembly nuts in the engine bay.
3. Fit the ABS, TCS or ESP unit bracket and connect the electrical switch connection.
4. Fit the ABS, TCS or ESP unit.
5. Fit the engine wiring harness and its holder and connect it.
6. Tighten the bolts for the pedal assembly/assemblies to the steering column assembly.





7. Fit the steering shaft UJ.
Tightening torque 25 Nm (18 ft. lbs.).
8. Fit the stepping motor.
9. Fit the pedal switches.





10. Fit the pin and clip and hook on the return spring.
11. Plug in the pedal switches and adjust them.
12. Fit the lower dashboard panel.
13. Reset the clock and radio code, etc.

Brake pedal, RHD
To remove
1. Move the seat all the way back.
2. Remove the brake servo unit.





3. Remove the retaining nuts from the brake servo bracket/pedal assembly.
4. Remove the dashboard.
5. Loosen the steering shaft UJ from the steering gear without separating the splines.
6. Unplug the pedal switch connections.
7. Undo the steering column assembly mounting to the body and pedal bracket, and move it as far back as possible.
8. Lift out the pedal assembly.

To fit
1. Fit the pedal assembly loosely to the steering column assembly and place the foam rubber damper in position between the pedal assemblies.
2. Fit the steering shaft UJ.
Tightening torque 25 Nm (18 ft. lbs.).





3. Tighten the pedal assembly nuts in the engine bay.
4. Fit the brake servo unit.
5. Fit the steering column assembly to the body.
6. Tighten the bolts for the pedal assembly/assemblies to the steering column assembly.
7. Fit the pedal switches.
8. Plug in the pedal switches and adjust them.
9. Fit the dashboard.
10. Reset the clock and radio code, etc.