Brake Pedal Assy: Service and Repair

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY





3. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS
a. Disconnect the stop lamp switch connector.
b. Remove the brake pedal return spring.
c. Remove the clip and the clevis pin and separate the master cylinder push rod clevis from the brake pedal sub-assembly.
4. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY





a. Remove the bolt from the brake pedal support assembly.





b. Remove the 4 nuts and the brake pedal support assembly.
5. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a. Remove the brake pedal shaft and the nut from the brake pedal support sub-assembly.
b. Remove the brake pedal sub-assembly and the 2 bushes.
6. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Loosen the stop lamp switch lock nut.
b. Remove the stop lamp switch assembly from the brake pedal support sub-assembly.
7. REMOVE BRAKE PEDAL PAD
a. Remove the brake pedal pad from the brake pedal support sub-assembly.
8. INSTALL BRAKE PEDAL PAD
a. Install the brake pedal pad to the brake pedal support sub-assembly.
9. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Install the stop lamp switch assembly with the nut.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





10. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a. Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushes.
b. Install the brake pedal sub-assembly and the 2 brake pedal busies on the brake pedal support with the brake pedal shaft and the nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
11. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY





a. Install the brake pedal support assembly with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





b. Install the bolt on the brake pedal support assembly.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)





12. CONNECT MASTER CYLINDER PUSH ROD CLEVIS
a. Apply lithium soap base glycol grease to the clevis pin.
b. Install the clevis pin and the clip.

NOTICE: The direction for the clip installation is as follows.

c. Install the brake pedal return spring.
d. Connect the stop lamp switch connector to the stop lamp switch assembly.
13. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
14. CHECK AND ADJUST BRAKE PEDAL HEIGHT
15. CHECK PEDAL FREE PLAY
16. CHECK PEDAL RESERVE DISTANCE
17. INSPECT SRS WARNING LIGHT (W/ SRS AIRBAG)