Brake Pedal Assy: Service and Repair

BRAKE PEDAL SUPPORT

COMPONENTS:

DISASSEMBLY
1. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

HINT: Refer to the procedures up to "REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY".

2. REMOVE BRAKE PEDAL RETURN SPRING
3. REMOVE PUSH ROD PIN
(a) Remove the clip and push rod pin.
4. REMOVE BRAKE PEDAL SUPPORT
(a) Disconnect the stop light switch connector.
(b) Remove the 2 bolts, 4 nuts and brake pedal support sub-assembly.
5. REMOVE STOP LIGHT SWITCH ASSEMBLY
(a) Loosen the stop light switch lock nut and remove the stop light switch assembly.
6. REMOVE BRAKE PEDAL SUB-ASSEMBLY
(a) Remove the nut, bolt and brake pedal sub-assembly from brake pedal support sub-assembly.
7. REMOVE BRAKE PEDAL PAD
8. REMOVE BRAKE PEDAL BUSHING
(a) Remove the 2 brake pedal bushings from brake pedal sub-assembly.
9. REMOVE STOP LIGHT SWITCH CUSHION

REASSEMBLY
1. INSTALL STOP LIGHT SWITCH CUSHION
2. INSTALL BRAKE PEDAL BUSHING
(a) Apply lithium soap base glycol grease to the parts indicated by arrows.
(b) Install 2 new brake pedal bushings to brake pedal sub-assembly.
3. INSTALL BRAKE PEDAL PAD
4. INSTALL BRAKE PEDAL SUB-ASSEMBLY
(a) Install the brake pedal sub-assembly with the bolt and nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
5. INSTALL STOP LIGHT SWITCH ASSEMBLY
(a) Install the stop light switch assembly with the stop light switch lock nut.

HINT: After adjusting the brake pedal height, torque the lock nut.

6. INSTALL BRAKE PEDAL SUPPORT
(a) Install the brake pedal support sub-assembly with the 2 bolts and 4 nuts.
Torque:
Bolt: 20 Nm (204 kgf-cm, 15 ft. lbs.)
Nut: 13 Nm (130 kgf-cm, 9 ft. lbs.)
7. INSTALL PUSH ROD PIN
(a) Apply lithium soap base glycol grease to the parts indicated by arrows.
(b) Install the push rod pin and clip.
(c) Connect the stop light switch connector.
8. INSTALL BRAKE PEDAL RETURN SPRING
9. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

HINT: Refer to the procedures up to "INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY".

10. CHECK AND ADJUST BRAKE PEDAL HEIGHT
11. CHECK PEDAL FREE PLAY
12. CHECK PEDAL RESERVE DISTANCE