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Brake Pedal Assy: Service and Repair






REPLACEMENT
1. REMOVE FRONT DOOR SCUFF PLATE LH
2. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER
3. REMOVE INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
4. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
5. REMOVE COMBINATION METER ASSEMBLY
6. REMOVE BRAKE PEDAL RETURN SPRING
a. Remove the brake pedal return spring.





7. REMOVE PUSH ROD PIN
a. Remove the clip and the push rod pin.
b. Disconnect the stop lamp switch connector.
c. Disconnect the pedal force switch connector and release the clip of the pedal force switch.





8. REMOVE BRAKE PEDAL SUPPORT ASSEMBLY
a. Remove the bolt, the 4 nuts and the brake pedal support assembly.
9. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a. Remove the nut, the brake pedal shaft and the brake pedal sub-assembly from the brake pedal support sub-assembly.
10. REMOVE BRAKE PEDAL PAD
a. Remove the brake pedal pad from the brake pedal sub-assembly.
11. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Loosen the stop lamp switch lock nut and remove the stop lamp switch assembly.





12. REMOVE BRAKE PEDAL BUSH
a. Remove the 2 brake pedal bushes from the brake pedal sub-assembly.
13. REMOVE BRAKE PEDAL SHAFT COLLAR
a. Remove the brake pedal shaft collar from the brake pedal sub-assembly.
14. REMOVE STOP LAMP SWITCH CUSHION
a. Remove the stop lamp switch cushion from the brake pedal sub-assembly.
15. INSTALL STOP LAMP SWITCH CUSHION
a. Install the stop lamp switch cushion to the brake pedal sub-assembly.





16. INSTALL BRAKE PEDAL SHAFT COLLAR
a. Apply lithium soap base glycol grease to the ends and sides of brake pedal shaft collar.
b. Install the brake pedal shaft collar to the brake pedal sub-assembly.
17. INSTALL BRAKE PEDAL BUSH
a. Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushes.
b. Install the new brake pedal bushes to the brake pedal
18. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Install the stop lamp switch assembly with the stop lamp switch lock nut.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

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

19. INSTALL BRAKE PEDAL PAD
a. Install the brake pedal pad to the brake pedal sub-assembly.
20. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a. Install the brake pedal sub-assembly with the brake pedal shaft and the nut.
Torque 37 Nm (375 kgf-cm, 27 ft. lbs.)





21. INSTALL BRAKE PEDAL SUPPORT ASSEMBLY
a. Install the brake pedal support assembly with the bolt and the 4 nuts.
Torque:
Bolt: 20 Nm (204 kgf-cm, 15 ft. lbs.)
Nut: 13 Nm (130 kgf-cm, 9 ft. lbs.)





22. INSTALL PUSH ROD PIN
a. Apply lithium soap base glycol grease to the clevis pin.
b. Install the clevis pin and the clip.
c. Connect the pedal force switch connector and install the clip of the pedal force switch to the brake pedal support sub-assembly.
d. Connect the stop lamp switch connector.
23. INSTALL BRAKE PEDAL RETURN SPRING
a. Install the brake pedal return spring.
24. CHECK AND ADJUST BRAKE PEDAL HEIGHT
25. CHECK PEDAL FREE PLAY
26. CHECK PEDAL RESERVE DISTANCE
27. INSTALL COMBINATION METER ASSEMBLY
28. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
29. INSTALL INSTRUMENT PANEL AIR BAG ASSEMBLY LOWER NO.1
30. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER
31. INSTALL FRONT DOOR SCUFF PLATE LH
32. INSPECT SRS WARNING LIGHT

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