Brake Pedal Assy: Service and Repair

PEDAL

REMOVAL





1. Disconnect and isolate battery negative cable (2) from battery post.





2. Remove brake lamp switch.
3. Remove booster push rod from pin on brake pedal. To do so:
a. Position small screwdriver between center tang on power brake booster brake pedal pin retaining clip (3).
b. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin, then slide retaining clip off brake pedal pin.
c. Discard retaining clip (3). It is not to be reused. Install NEW retaining clip when assembling.
4. Slide booster push rod (5) off brake pedal pin (4).





5. Remove four power brake booster (3) mounting nuts (1).
6. Remove two nuts (1) fastening pedal bracket to upper dash panel (2).
7. Push power brake booster (3) forward into engine compartment as far as possible by hand. Do not force it.
8. Remove brake pedal (4).

INSTALLATION





1. Install adjustable brake pedal assembly (4) under instrument panel and slide over booster push rod.
2. From engine compartment side, push power brake booster (3) mounting studs back through dash panel (2) and brake pedal bracket.
3. Install two upper mounting nuts (1) fastening pedal bracket to upper dash panel (2). Do not tighten at this time.
4. Install four power brake booster mounting nuts (1). Tighten nuts to 25 Nm (18 ft. lbs.) torque.
5. Tighten two upper mounting nuts (1) to 25 Nm (18 ft. lbs.) torque.





6. Slide booster push rod (5) onto brake pedal pin (4). Install NEW retaining clip (3) securing push rod to brake pedal.
7. Install and adjust NEW brake lamp switch (2).





8. Connect battery negative cable (2) to battery post. It is important that this is performed properly.
9. Road test vehicle testing operation of brakes.