Brake Pedal Assy: Service and Repair

BRAKE PEDAL
OVERHAUL
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY

HINT: Refer to the procedures from the removal of the instrument panel register assy No.1 up until the removal of the instrument panel sub-assy w/ passenger airbag assy.

3. REMOVE MASTER CYLINDER PUSH ROD CLEVIS





a) Remove the brake pedal return spring.
b) Remove the clip and brake master cylinder push rod pin.
c) Separate the push rod clevis from the brake pedal sub assy.
4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSY





a) Disconnect the connector from the stop lamp switch assy.
b) Disconnect the connector from the brake pedal stroke sensor.
c) Remove the bolt from the instrument panel upper panel side.





d) Remove the 4 nuts and the brake pedal support sub assy.
5. REMOVE BRAKE PEDAL PAD
6. REMOVE STOP LAMP SWITCH ASSY





a) Loosen the stop lamp switch lock nut and remove the stop lamp switch assy from the brake pedal support sub-assy.
7. REMOVE BRAKE PEDAL STROKE SENSOR ASSY





a) Remove the 2 bolts and separate the brake pedal stroke sensor from the brake pedal support sub-assy.
8. REMOVE BRAKE PEDAL SUB-ASSY
a) Remove the nut from the brake pedal shaft.
b) Remove the brake pedal shaft and separate the brake pedal from the brake pedal support sub-assy.
c) Remove the 2 brake pedal bushes from the brake pedal sub-assy.
d) Remove the brake pedal shaft collar from the brake pedal shaft.
9. INSTALL BRAKE PEDAL SUB-ASSY
a) Apply lithium soap base glycol grease to the 2 new brake pedal bushes. Install the brake pedal bushes to the brake pedal sub-assy.
b) Install the brake pedal shaft collar to the brake pedal shaft.
c) Install the brake pedal to the brake pedal support with the brake pedal shaft and a nut.
Torque: 37 Nm (375 kgf-cm, 27 ft. lbs.)
10. INSTALL BRAKE PEDAL STROKE SENSOR ASSY





a) Install the brake pedal stroke sensor to the brake pedal support sub-assy with the 2 bolts.

HINT: Tighten the bolts when checking and adjusting the brake pedal height.

11. INSTALL STOP LAMP SWITCH ASSY





a) Turn the stop lamp switch assy clockwise and install it to the brake pedal support sub-assy.

HINT: Tighten the lock nut when checking and adjusting the brake pedal height.

12. INSTALL BRAKE PEDAL PAD
13. INSTALL BRAKE PEDAL SUPPORT SUB-ASSY





a) Install the brake pedal support with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





b) Install the brake pedal support from the instrument panel side with a bolt.
Torque: 24 Nm (241 kgf-cm, 18 ft. lbs.)
c) Connect the connector to the stop lamp switch assy.
d) Connect the connector to the brake pedal stroke.
14. INSTALL MASTER CYLINDER PUSH ROD CLEVIS





a) Apply lithium soap base glycol grease to the circumference of the brake master cylinder push rod pin.
b) Install the push rod clevis to the brake pedal with the brake master cylinder push rod pin.
c) Install the clip and brake pedal return spring.
15. INSTALL INSTRUMENT PANEL SUB-ASSY W/PASSENGER AIRBAG ASSY
16. CHECK AND ADJUST BRAKE PEDAL HEIGHT
17. CHECK PEDAL FREE PLAY
18. CHECK PEDAL RESERVE DISTANCE