Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement

Removal Procedure

Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Remove the knee bolster. Refer to Knee Bolster Replacement (Service and Repair) .
2. Remove the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side (LHD) (Service and Repair) .
3. Remove the instrument panel retainer. Refer to Instrument Panel Retainer Replacement (Service and Repair) .
4. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement (Master Cylinder Replacement) .
5. Remove the vacuum hose and check valve from the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement (6.0L Engine) (Power Brake Booster Inlet Hose Replacement (6.0L Engine))Power Brake Booster Inlet Hose Replacement (3.6L Engine) (Power Brake Booster Inlet Hose Replacement (3.6L Engine)) .
6. Remove the brake pedal position sensor. Refer to Stop Lamp Switch Replacement (Service and Repair) .




7. Remove the brake pedal pushrod retaining clip (1), washer (2) and the brake pedal pushrod (3) from the brake pedal (4).




8. Remove the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Important: From the engine compartment, pull the vacuum brake booster forward to release the four studs from the bulkhead and brake pedal support bracket.


9. Remove the vacuum brake booster from the vehicle.




10. Remove the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).

Important: Lower the brake pedal assembly rear end first to aid in removal.


11. Remove the brake pedal assembly from under the instrument panel.



Installation Procedure


Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .






Important: Raise the brake pedal assembly front end first for installation.


1. Install the brake pedal assembly.
2. Install the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).
DO NOT fully tighten at this stage.
3. Have an assistant install the vacuum brake booster from the engine compartment. Make sure the vacuum brake booster's four studs are correctly located in the bulkhead and brake pedal support bracket.




4. Install the push rod (3), washer (2) and retaining clip (1) to the brake pedal assembly (4).





Notice: Refer to Fastener Notice (Fastener Notice) .

5. Install the vacuum brake booster to brake pedal support bracket retaining nuts (1).

Tighten the nuts to 22 Nm. (16 lb ft)





6. Tighten the two brake pedal bracket assembly to cross car beam retaining bolts (1).

Tighten the bolts to 23 Nm. (17 lb ft.)

7. Install the brake pedal position sensor. Refer to Stop Lamp Switch Replacement (Service and Repair) .
8. Install the vacuum hose and check valve to the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement (6.0L Engine) (Power Brake Booster Inlet Hose Replacement (6.0L Engine))Power Brake Booster Inlet Hose Replacement (3.6L Engine) (Power Brake Booster Inlet Hose Replacement (3.6L Engine)) .
9. Install the master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement) .
10. Bleed the braking system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .
11. Install the instrument panel retainer. Refer to Instrument Panel Retainer Replacement (Service and Repair) .
12. Install the instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side (LHD) (Service and Repair) .
13. Install the instrument panel lower trim panel assembly. Refer to Knee Bolster Replacement (Service and Repair) .
14. Road test the vehicle to inspect correct brake, stop lamp and cruise control operation.