Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement

Removal Procedure

Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).

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


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

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

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 (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) (Power Brake Booster Inlet Hose Replacement)Power Brake Booster Inlet Hose Replacement (3.6L) (Power Brake Booster Inlet Hose Replacement).
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).

Note: 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 2 brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).

Note: 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





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

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

Note: 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 4 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).





Caution: Refer to Fastener Caution (Fastener Caution).

5. Install the vacuum brake booster to brake pedal support bracket retaining nuts (1) and tighten to 22 Nm. (16 lb ft).




6. Tighten the 2 brake pedal bracket assembly to cross car beam retaining bolts (1) 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) (Power Brake Booster Inlet Hose Replacement)Power Brake Booster Inlet Hose Replacement (3.6L) (Power Brake Booster Inlet Hose Replacement).
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 (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.