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 LOWER INSTRUMENT PANEL ASSEMBLY





3. DISCONNECT MASTER CYLINDER PUSH ROD CLEVIS
a) Disconnect the stop light switch connector.
b) Remove the brake pedal return spring.
c) Remove the clip and clevis pin, and disconnect the master cylinder push rod clevis from the brake pedal.





4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a) Remove the bolt from the brake pedal support.





b) Remove the 4 nuts and brake pedal support.
5. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a) Remove the brake pedal shaft and nut from the brake pedal support.
b) Remove the brake pedal and 2 bushes.
c) Remove the stop lamp switch cushion.
6. REMOVE STOP LIGHT SWITCH ASSEMBLY
a) Loosen the stop light switch lock nut.
b) Remove the stop light switch from the brake pedal support.
7. REMOVE BRAKE PEDAL PAD
a) Remove the brake pedal pad from the brake pedal.

INSTALLATION
1. INSTALL BRAKE PEDAL PAD
a) Install the brake pedal pad to the brake pedal.
2. INSTALL STOP LIGHT SWITCH ASSEMBLY
a) Install the stop light switch to the support with the nut.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





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





4. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a) Install the brake pedal support with the 4 nuts.
Torque: 13 Nm (127 kgf-cm, 9 ft. lbs.)





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





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

NOTICE: The direction for the clip installation is as shown in the illustration.

c) Install the brake pedal return spring.
d) Connect the stop light switch connector to the stop light switch.
6. INSTALL LOWER INSTRUMENT PANEL ASSEMBLY
a) Install the instrument panel.
7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
8. CHECK AND ADJUST BRAKE PEDAL HEIGHT
9. CHECK BRAKE PEDAL FREE PLAY
10. CHECK BRAKE PEDAL RESERVE DISTANCE
11. CHECK SRS WARNING LIGHT (w/SRS Airbag)
a) Check the SRS warning light.