Brake Pedal Assy: Service and Repair

BRAKE PEDAL

COMPONENTS:

REMOVAL
1. REMOVE COMBINATION METER ASSEMBLY
(a) Remove the combination meter assembly.
2. DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Remove the clip, push rod clevis pin and wave washer, and disconnect the push rod clevis from the brake pedal.





3. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
(a) Remove the bolt from the brake pedal support.
(b) Disconnect the stop light switch connector.





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

INSTALLATION
1. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub-assembly.
2. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Install the stop light switch assembly to the brake pedal sub-assembly.
3. INSTALL BRAKE PEDAL SUB-ASSEMBLY
(a) Apply the lithium soap base glycol grease to the 2 new bushes on the ends and sides.
(b) Install the brake pedal sub-assembly and 2 bushes to the brake pedal support with the bolt and nut.
Torque: 36.8 N*m (375 kgf*cm, 27 ft.*lbf)





4. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
(a) Install the brake pedal support assembly with the 4 nuts.
Torque: 12.7 N*m (130 kgf*cm, 9 ft.*lbf)
(b) Connect the stop light switch connector to the stop light switch assembly.





(c) Install the bolt to the brake pedal support.
Torque: 23.6 N*m (240 kgf*cm, 17 ft.*lbf)
5. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Apply the lithium soap base glycol grease to the push rod clevis pin.
(b) Connect the brake master cylinder push rod clevis with the push rod clevis pin, wave washer and clip.
6. INSTALL COMBINATION METER ASSEMBLY
7. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Check and adjust the brake pedal height.
8. CHECK BRAKE PEDAL FREE PLAY
(a) Check the brake pedal free play.
9. CHECK PEDAL RESERVE DISTANCE
(a) Check the pedal reserve distance.