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Brake Pedal Assy: Service and Repair

BRAKE PEDAL

COMPONENTS:





REMOVAL
1. REMOVE FRONT DOOR SCUFF PLATE LH
2. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER
3. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY
4. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
5. REMOVE COMBINATION METER ASSEMBLY
6. REMOVE BRAKE PEDAL RETURN SPRING





7. REMOVE PUSH ROD PIN
a. Remove the clip and the push rod pin.
b. Disconnect the stop light 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

DISASSEMBLY
1. REMOVE BRAKE PEDAL PAD
2. REMOVE STOP LIGHT SWITCH ASSEMBLY
a. Loosen the stop light switch lock nut and remove the stop light switch assembly.





3. REMOVE BRAKE PEDAL BUSH
a. Remove the 2 brake pedal bushes from the brake pedal sub-assembly.
4. REMOVE BRAKE PEDAL SHAFT COLLAR
a. Remove the brake pedal shaft from the brake pedal sub-assembly.
5. REMOVE STOP LIGHT SWITCH CUSHION
a. Remove the stoplight switch cushion from the brake pedal sub-assembly.

REASSEMBLY
1. INSTALL STOP LIGHT SWITCH CUSHION
a. Install the stop light switch cushion to the brake pedal sub-assembly.





2. 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 new brake pedal shaft collar to the brake pedal sub-assembly.
3. 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 sub-assembly.
4. INSTALL STOP LIGHT SWITCH ASSEMBLY
a. Install the stop light switch assembly with the stop light switch lock nut.
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)

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

5. INSTALL BRAKE PEDAL PAD
a. Install the brake pedal pad to the brake pedal subassembly.

INSTALLATION
1. 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.)





2. 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.)





3. 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 light switch connector.
4. INSTALL BRAKE PEDAL RETURN SPRING
5. CHECK AND ADJUST BRAKE PEDAL HEIGHT
6. CHECK PEDAL FREE PLAY
7. CHECK PEDAL RESERVE DISTANCE
8. INSTALL COMBINATION METER ASSEMBLY
9. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY
10. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
11. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER
12. INSTALL FRONT DOOR SCUFF PLATE LH
13. INSPECT SRS WARNING LIGHT
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