Brake Pedal Assy: Service and Repair

BRAKE PEDAL

COMPONENTS:

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. REMOVE METER HOOD SUB-ASSEMBLY
3. REMOVE COMBINATION METER ASSEMBLY
4. DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
a) Remove the return spring.
b) Remove the clip and clevis pin.
c) Disconnect the push rod clevis from the brake pedal.
5. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a) Disconnect the stop light switch connector.
b) Disconnect the wire harness clamp from the pedal support.





c) Remove the bolt from the pedal support.





d) Remove the 4 nuts and pedal support.
6. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a) Remove the nut, brake pedal shaft and brake pedal.
b) Remove the 2 bushes from the brake pedal.
7. REMOVE STOP LIGHT SWITCH ASSEMBLY
a) Turn the switch counterclockwise and remove it.
b) Remove the mounting adjuster from the pedal support.
8. REMOVE BRAKE PEDAL PAD

INSTALLATION
1. INSTALL BRAKE PEDAL PAD





2. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a) Apply lithium soap base glycol grease to 2 new bushes.
b) Install them to the brake pedal.
c) Install the brake pedal to the pedal shaft with the nut and brake pedal shaft.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)





3. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a) Install the pedal support with the 4 nuts.
Torque: 12.7 Nm (130 kgf-cm, 9 ft. lbs.)
b) Install the bolt to the support.
Torque: 24 Nm (241 kgf-cm, 17 ft. lbs.)





4. CONNECT 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 clip.
c) Install the return spring.





5. INSTALL STOP LIGHT SWITCH ASSEMBLY
a) Install the mounting adjuster to the pedal support .
b) Insert the switch into the mounting adjuster until it slightly touches the pedal.

NOTICE: Do not depress the pedal.





c) Turn the switch a quarter turn clockwise.
Torque: 1.5 Nm (15 kgf-cm, 13 inch lbs.)

NOTICE: Do not depress the pedal.

d) Connect the wire harness clamp to the pedal support.
e) Connect the switch connector to the switch.
f) Check the switch clearance.
Standard stop light switch clearance: 1.5 to 2.5 mm (0.059 to 0.098 inch)
6. CHECK AND ADJUST BRAKE PEDAL HEIGHT
7. CHECK BRAKE PEDAL FREE PLAY
8. CHECK BRAKE PEDAL RESERVE DISTANCE
9. INSTALL COMBINATION METER ASSEMBLY
10. INSTALL METER HOOD SUB-ASSEMBLY
11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
12. PERFORM INITIALIZATION
a) Perform initialization.

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.