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Brake Pedal and Bracket: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the brake pedal assembly in the vehicle.
  2. Position the instrument panel and install the 4 instrument panel to cowl support bolts.
    • Tighten to 25 Nm (18 lb-ft).
  3. Connect the steering shafts and install the pinch bolt.
    • Tighten to 30 Nm (22 lb-ft).
  4. Connect the bulkhead electrical connectors and tighten the bolt.
  5. Position the steering column opening cover and install the 2 screws.
  6. Install the instrument panel duct support bolt and the instrument panel-to-cowl support bolt.
    1. Tighten to 9 Nm (80 lb-in).
    2. Tighten to 30 Nm (22 lb-ft).
      Fig 1: Tightening Bolt
      G03944796Courtesy of FORD MOTOR CO.
  7. Install the defroster grille.
  8. Install the 2 windshield side garnish mouldings.
  9. Position the 2 A-pillar passenger assist handles and install the 4 bolts.
    • Tighten to 11 Nm (8 lb-ft).
  10. Install the 4 A-pillar passenger assist handles caps.
  11. Install the 2 instrument panel side finish panels.
  12. Install the 2 A-pillar lower trim panels and the retainers.
  13. Install the 2 door scuff plates.
  14. Install the 4 instrument panel support bracket bolts in the LH and RH instrument support brackets.
  15. Install the instrument panel support bolt.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 2: Installing Instrument Panel Support Bolt
      G03944792Courtesy of FORD MOTOR CO.
  16. Install the cowl grille.
  17. Install the 2 wiper arms.
  18. Install the front floor console. For additional information, refer to INSTRUMENT PANEL AND CONSOLE .
  19. Install the 3 brake pedal bracket nuts.
    • Tighten to 7 Nm (62 lb-in).
  20. Position the brake master cylinder and brake booster assembly into the brake pedal bracket assembly.
  21. Install the 4 new brake booster nuts.
    • Tighten to 22 Nm (16 lb-ft).
  22. If equipped with power adjustable pedals, connect the adjustable pedal motor electrical connector.
  23. If equipped with adjustable pedals, connect the accelerator pedal electrical connector.
  24. Connect the brake booster rod and position the stoplamp switch, bushing, and spacers on the brake pedal.
  25. Install the redundant self-locking pin and cover.
    26. CAUTION: The brake pedal must be connected to the brake booster rod, in an at-rest position, before installing the speed control deactivator switch or the switch will be damaged.
  26. If equipped, install the speed control deactivator switch.
  27. Repower the supplemental restraint system (SRS). For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
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