Brake Pedal Assy: Service and Repair

Removing and installing


CAUTION: Brake pedal travel must not be restricted by floor mats.

Note: Grease all mountings before installing with white lubricating paste, Part No. AOS 126 000 06.

1. Cap
2. Brake fluid reservoir
^ With strainer
^ For vehicles with brake fluid warning indicator contact pin in reservoir
3. Rubber grommets
^ Moisten with brake fluid and press into reservoir.
4. Hex nut, 20 Nm (15 ft. lbs.)
5. Brake master cylinder, 23.81 mm diameter
^ Can not be repaired, replace completely if needed.
6. O-ring
^ Replace
7. Lock washer
^ Check for secure fit
8. Bolt
9. Self-locking hex nut, 25 Nm (18 ft. lbs.)
^ Replace
10. Brake booster push rod clevis
11. Brake booster
^ Before removing, remove Battery and disconnect brake lines
^ Gas engine intake manifold is vacuum source.
^ Diesel engines use a vacuum pump to create vacuum.
^ Function check
- With engine switched off, depress brake pedal firmly several times (to deplete vacuum in the unit).
- Depress brake pedal with normal foot pressure and hold.
^ Start engine. If booster is working properly, pedal will give slightly under foot (booster assistance becomes effective).
^ If faulty replace complete.
^ Non-return valve (in vacuum hose)
12. Seal
13. Securing clip
14. Brake pedal return spring
15. Brake pedal bushing
16. Brake pedal
17. Brake pedal pivot pin
18. Brake Light Switch
^ Before installing Brake Light Switch, connect brake pedal to brake booster push rod
^ Before installing, pull plunger out completely
^ Guide switch through hole and secure by turning clockwise 90°
19. Hex bolt, 25 Nm (18 ft. lbs.)
20. Bracket
21. Hex bolt, 25 Nm (18 ft. lbs.)
22. Bracket
23. Front body panel