Brake Pedal Assy: Service and Repair
BRAKE PEDAL SUB-ASSEMBLY
REPLACEMENT
1. REMOVE METER HOOD SUB-ASSEMBLY
2. REMOVE COMBINATION METER ASSEMBLY
3. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Remove the return spring.
b. Remove the clip and the clevis pin, and separate the push rod clevis from the brake pedal sub-assembly.
4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a. Disconnect the stop lamp switch connector.
b. Separate the wire harness clamp from the pedal support sub-assembly.
c. Remove the bolt from the pedal support sub-assembly.
d. Remove the 4 nuts and pedal support sub-assembly.
5. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a. Remove the nut, brake pedal shaft, and brake pedal sub-assembly.
b. Remove the 2 bushes from the brake pedal sub-assembly.
6. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Turn the stop lamp switch assembly counterclockwise and remove it.
b. Remove the mounting adjuster from the pedal support sub-assembly.
7. REMOVE BRAKE PEDAL PAD
8. INSTALL BRAKE PEDAL PAD
9. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a. Apply lithium soap base glycol grease to 2 new bushes.
b. Install them to the brake pedal sub-assembly.
c. Install the brake pedal sub-assembly to the pedal support sub-assembly with the nut and brake pedal shaft.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
10. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a. Install the pedal support sub-assembly with the 4 nuts.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install the bolt to the pedal support sub-assembly.
Torque: 24 Nm (241 kgf-cm, 17 ft. lbs.)
11. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a. Apply lithium soap base glycol grease to the clevis pin.
b. Install the push rod clevis with the clevis pin and the clip.
c. Install the return spring.
12. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Install the mounting adjuster to the pedal support sub-assembly.
b. Insert the stop lamp switch assembly to the adjuster until it slightly touches the pedal sub-assembly.
NOTICE: Do not depress the brake pedal.
c. Make a quarter turn clockwise to install the stop lamp switch assembly.
NOTICE: Do not depress the brake pedal.
HINT: The turning torque for installing the stop lamp switch assembly.
Torque: 1.5 Nm (15 kgf-cm, 13 inch lbs.) or less
d. Install the wire harness clamp to the pedal support sub-assembly.
e. Connect the stop lamp switch connector to the stop lamp switch assembly.
13. INSTALL COMBINATION METER ASSEMBLY
14. INSTALL METER HOOD SUB-ASSEMBLY
15. CHECK AND ADJUST BRAKE PEDAL HEIGHT
16. CHECK PEDAL FREE PLAY
17. CHECK PEDAL RESERVE DISTANCE