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Brake Pedal Assy: Service and Repair

BRAKE PEDAL SUB-ASSEMBLY








COMPONENTS

REPLACEMENT
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
2. REMOVE FRONT FLOOR FOOTREST
3. REMOVE FRONT DOOR SCUFF PLATE LH
4. REMOVE COWL SIDE TRIM BOARD LH
5. REMOVE INSTRUMENT PANEL UNDER TRAY (AUTOMATIC TRANSAXLE)
6. REMOVE INSTRUMENT PANEL HOLE COVER (MANUAL TRANSAXLE)
7. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER NO.1
8. SEPARATE DRIVER SIDE JUNCTION BLOCK





9. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS
a. Remove the clip and push rod pin, then separate the push rod clevis.





10. REMOVE BRAKE PEDAL SUPPORT REINFORCEMENT
a. Remove the bolt from the reinforcement.





b. Remove the bolt and nut, then remove the reinforcement from the brake pedal support.
11. REMOVE BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a. Disconnect the stop lamp switch connector from the stop lamp switch.





b. Remove the 4 nuts and brake pedal support.





12. REMOVE BRAKE PEDAL RETURN SPRING
a. Remove the return spring from the brake pedal support and brake pedal.
13. REMOVE STOP LAMP SWITCH ASSEMBLY
a. Turn the stop lamp switch counterclockwise, and remove the stop lamp switch.
b. Remove the stop lamp switch mounting adjuster from the brake pedal support.





14. REMOVE BRAKE PEDAL SUB-ASSEMBLY
a. Remove the bolt and nut, then remove the brake pedal from the brake pedal support.
b. Remove the 4 brake pedal bushes from the brake pedal and brake pedal lever.
c. Remove the 2 collars from the brake pedal and brake pedal lever.





15. REMOVE BRAKE PEDAL LEVER
a. Using a screwdriver, remove the 2 E-rings from the brake pedal link pin.
b. Remove the 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal links.
c. Remove the brake pedal lever from the brake pedal.
16. REMOVE BRAKE PEDAL PAD
a. Remove the brake pedal pad from the brake pedal.
17. INSTALL BRAKE PEDAL PAD
a. Install the brake pedal pad onto the brake pedal.
18. INSTALL BRAKE PEDAL LEVER
a. Apply lithium soap base glycol grease to the 2 brake pedal link pins, 2 pedal shaft collars and 2 brake pedal links.
b. Install the brake pedal lever with the 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal links onto the brake pedal.
c. Install 2 new E-rings onto each brake pedal link pin.
19. INSTALL BRAKE PEDAL SUB-ASSEMBLY
a. Apply lithium soap base glycol grease to the 2 collars and 4 brake pedal bushes.
b. Install the 2 collars and 4 brake pedal bushes onto the brake pedal and brake pedal lever.





c. Install the brake pedal with the bolt and nut onto the brake pedal support.
Torque: 34.3 Nm (350 kgf-cm, 25 ft. lbs.)





20. INSTALL STOP LAMP SWITCH ASSEMBLY
a. Insert the stop lamp switch until the body comes into contact with the cushion.

NOTICE: When inserting the stop lamp switch, support the pedal from behind so that the pedal is not pushed in.





b. Make a quarter turn clockwise to install the stop lamp switch.

NOTICE: The turning torque for installing the stop lamp switch:

Torque: 1.5 Nm (15 kgf-cm, 13 inch lbs.) or less

HINT: Due to the inverse screw structure, turning the stop lamp switch clockwise will cause it to become loose and eventually detach from the adjuster.

c. Check the protrusion of the rod.
Protrusion of the rod: 1.5 to 2.5 mm (0.059 to 0.098 inch)
21. INSTALL BRAKE PEDAL RETURN SPRING
a. Apply lithium soap base glycol grease to the inner surface of the hole on the brake pedal support and brake pedal.
b. Install the return spring onto the brake pedal support and brake pedal.





22. INSTALL BRAKE PEDAL SUPPORT SUB-ASSEMBLY
a. Install the 4 nuts and brake pedal support.
Torque: 14.2 Nm (145 kgf-cm, 10 ft. lbs.)
b. Connect the stop lamp switch connector to the stop lamp switch.
23. INSTALL BRAKE PEDAL SUPPORT REINFORCEMENT
a. Install the reinforcement onto the brake pedal support.





b. Provisionally tighten the bolt and nut to the brake pedal support, reinforcement and brake pedal lever.





c. Install the bolt onto the reinforcement.
Torque: 34.3 Nm (350 kgf-cm, 25 ft. lbs.)
d. Tighten the bolt and nut.
Torque: 34.3 Nm (350 kgf-cm, 25 ft. lbs.)
24. INSTALL MASTER CYLINDER PUSH ROD CLEVIS
a. Apply lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever.
b. Install the push rod clevis onto the brake pedal lever with the push rod pin and clip.
25. CHECK BRAKE PEDAL HEIGHT
26. CHECK PEDAL FREE PLAY
27. CHECK PEDAL RESERVE DISTANCE
28. INSTALL DRIVER SIDE JUNCTION BLOCK
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
29. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER NO.1
30. INSTALL INSTRUMENT PANEL UNDER TRAY (AUTOMATIC TRANSAXLE)
31. INSTALL INSTRUMENT PANEL HOLE COVER (MANUAL TRANSAXLE)
32. INSTALL COWL SIDE TRIM BOARD LH
33. INSTALL FRONT DOOR SCUFF PLATE LH
34. INSTALL FRONT FLOOR FOOTREST
35. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 3.9 Nm (40 kgf-cm, 35 inch lbs.)
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