Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement
Removal Procedure
1. Remove the left side insulator panel.
2. Remove the knee bolster.
3. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 3.
4. Disconnect the electrical connector from the stop lamp switch.
5. Remove the booster push rod retain clip and washer (2) from the brake pedal assembly.
6. Remove the accelerator pedal.





7. Remove the booster push rod (2) from the brake pedal (1).
8. Remove the brake booster mounting nuts (3).
9. Remove the digital radio receiver and bracket if equipped.





10. Remove the brake pedal brace (4) mounting nuts (1).
11. Remove the brake pedal brace (4) mounting bolt.
12. Remove the brake pedal assembly mounting nuts (2).
13. Pull master cylinder and brake booster assembly forward for additional clearance while removing brake pedal assembly.
14. Remove the brake pedal assembly with the bracket (4).
15. Remove the brake pedal assembly (3) from the vehicle.
16. Remove the brake pedal position sensor from the brake pedal assembly.

Installation Procedure
1. Install the brake pedal position sensor to the brake pedal assembly.





2. Notice: Refer to Fastener Notice.

Position the brake pedal brace (4) to the brake pedal assembly and install the brace mounting nuts (1).
Tighten the nuts to 10 Nm (89 inch lbs.).
3. Install the brake pedal assembly (3) with the brace to the vehicle.
4. Push the master cylinder and brake booster assembly back into position.
5. Install the brake pedal brace (4) upper mounting bolt.
Tighten the bolt to 10 Nm (89 inch lbs.).
6. Install the brake pedal assembly mounting nuts (2).
Tighten the nuts (2) to 25 Nm (18 ft. lbs.).
7. Install the digital radio receiver and bracket if equipped.





8. Install the brake booster mounting nuts (3).
Tighten the nuts (3) to 25 Nm (18 ft. lbs.).
9. Install the booster push rod (2) to the brake pedal (1).
10. Install washer and retain clip.
11. Install the accelerator pedal.
12. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3.
13. Connect the electrical connector to the stop lamp switch.
14. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
15. Install the knee bolster.
16. Install the left side insulator panel.