Brake Pedal and Bracket - Manual Transmission

Removal





All vehicles
1. Detach the instrument panel lower panel.
1 Remove the screws.
2 Release the fastener.





2. Remove the instrument panel lower panel. Disconnect the Data Link Connector (DLC). Disconnect the footwell lamp electrical connector (if equipped).





3. Disconnect the electrical connectors from the pedal position switches.
1 Speed control deactivation switch (if equipped).
2 Stop lamp switch.
3 Clutch position switch.





4. Remove the pedal position switches.
1 Speed control deactivation switch (colored green) (if equipped).
2 Stop lamp switch (colored grey).
3 Clutch position switch (colored red).





5. Detach the clutch master cylinder from the pedal bracket (clutch position switch bracket shown removed for clarity).
1 Remove the clip.
2 Remove the bolts.





6. Detach the clutch master cylinder actuating rod from the clutch pedal.





7. Remove the brake booster retaining nuts (clutch position switch bracket shown removed for clarity).





8. Detach the brake booster actuating rod from the brake pedal.
1 Depress the brake pedal.
2 Depress the clip.
3 Remove and discard the brake booster actuating rod pin.





Right-hand drive vehicles built up to 12/1998
9. Disconnect the steering column shaft from the steering gear pinion extension.
1 Loosen the upper bolt.
2 Remove the lower bolt.
3 Move the sleeve upwards.





Right-hand drive vehicles built 12/1998 onwards

10. NOTE: Make sure the road wheels are in the straight ahead position.

Centralize the steering and lock it in position.





11. Disconnect the steering column shaft from the steering gear pinion extension.
1 Remove and discard the bolt.
2 Release the pinion shaft extension from the steering column.





Vehicles built 01/1999 onwards
12. Remove the brake pedal retractor arm retaining bolt.
^ Remove the air duct, if necessary.

All vehicles
13. Remove the brake pedal bracket.

Installation
All vehicles

1. NOTE: Make sure the brake pedal locates into the brake booster actuating rod clevis.

Install the brake pedal bracket.





2. NOTE: Do not fully tighten the brake booster retaining nuts at this stage.

Install the brake booster retaining nuts (clutch position switch bracket shown removed for clarity).





Vehicles built 01/1999 onwards

3. NOTE: Do not fully tighten the brake pedal retractor arm retaining bolt at this stage.

Install the brake pedal retractor arm retaining bolt.





4. CAUTION: Make sure there is clearance between the brake pedal and the brake pedal retractor to allow free movement.

Align the brake pedal retractor arm to the brake pedal bracket.





All vehicles
5. Tighten the brake booster retaining nuts (clutch position switch bracket shown removed for clarity).





Vehicles built 01/1999 onwards
6. Tighten the brake pedal retractor arm retaining bolt.
^ Install the air duct, if necessary.
7. With the engine running depress the brake pedal three times to make sure the brake pedal moves freely and returns to the full brake off position.





Right-hand drive vehicles built up to 12/1998

8. WARNING: Install a new steering column pinch bolt. Failure to follow this instruction may result in personal injury.

Connect the steering column shaft to the steering gear pinion extension.
1 Move the sleeve downwards.
2 Tighten the bolts.




Right-hand drive vehicles built 12/1998 onwards

9. WARNING: Install a new steering column pinch bolt. Failure to follow this instruction may result in personal injury.

Connect the steering column shaft to the steering gear pinion extension.





All vehicles
10. Attach the clutch master cylinder actuating rod to the clutch pedal.





11. NOTE: Locate the clutch master cylinder into the pedal bracket holes.

Attach the clutch master cylinder to the pedal bracket (clutch position switch bracket shown removed for clarity).
1 Install the bolts.
2 Install the clip.





12. CAUTION: Install a new brake booster actuating rod pin.

Install the brake booster actuating rod pin.
1 Depress the brake pedal.
2 Install the brake booster actuating rod pin.





13. NOTE: The clutch position switch (colored red) is not adjustable.

Pull out the speed control deactivation switch (if equipped) and stop lamp switch plungers until they are fully extended.
^ Measure the plunger length.
^ Speed control deactivation switch (colored green) XX mm = 24 mm.
^ Stop lamp switch (colored grey) XX mm = 21 mm.





14. CAUTION: When installing the switches, the stop lamp switch is rotated counterclockwise and the remaining switches are rotated clockwise. Failure to follow this instruction will result in the switch plungers binding inside the switch. Make sure the switches are correctly installed.

NOTE: The speed control deactivation switch (if equipped) and the stop lamp switch are automatically adjusted during installation. A slight ratcheting noise and feel during installation of the speed control deactivation switch (if equipped) and the stop lamp switch is normal.

Install the pedal position switches.
1 Clutch position switch (colored red).
2 Stop lamp switch (colored grey).
3 Speed control deactivation switch (colored green) (if equipped).





15. NOTE: The colors of the electrical connectors and switches are identical.

Connect the electrical connectors to the pedal switches.
1 Speed control deactivation switch (if equipped).
2 Stop lamp switch.
3 Clutch position switch.





16. Connect the Data Link Connector (DLC) and the footwell lamp (if equipped) electrical connectors.





17. Install the instrument panel lower panel.
1 Secure the fastener.
2 Install the screws.