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Removal & Installation (2003-04 A/T)

NOTE: This procedure removes the brake pedal bracket also.
  1. Remove lower instrument panel retaining screws. Release clip. See Figure.
  2. Disconnect hood release cable. Disconnect data link connector from lower instrument panel. See Figure. Remove lower instrument panel.
  3. Disconnect the speed control deactivation switch (if equipped) and brakelight switch harness connectors. See Fig 1.
  4. Remove the speed control deactivation switch (if equipped) and brakelight switch.
  5. Remove the brake booster retaining nuts. See Figure.
  6. Disconnect the brake booster actuating rod from the brake pedal. Depress the brake pedal. Depress the clip. Remove and discard the brake booster actuating rod pin.
  7. Remove the brake pedal retractor arm retaining bolt. See Figure. Remove the air duct, if necessary.
  8. Remove the brake pedal bracket.
  9. To install, reverse removal procedure. When installing the brake booster retaining nuts, do not tighten nuts at this time. Install a NEW brake booster actuating rod pin.
  10. When installing the brake pedal retractor arm retaining bolt, do not fully tighten the retaining bolt at this time. Align the brake pedal retractor arm to the brake pedal bracket. See Figure. Ensure there is clearance between the brake pedal and the brake pedal retractor to allow free movement.
  11. Tighten the brake booster retaining nuts.
  12. Tighten the brake pedal retractor arm retaining bolt.
  13. With the engine running depress the brake pedal 3 times to ensure the brake pedal moves freely and returns to the full brake off position.
    14. NOTE: When installing the pedal switches, ensure switches are installed correctly. The brakelight switch (Gray) rotates counterclockwise to install and the speed control deactivation switch (Green) rotate clockwise to install. If switches are not installed correctly, the switch plungers will bind inside the switch.
    NOTE: A slight ratcheting noise and feel during installation of the speed control deactivation switch and the brakelight switch is normal.
    NOTE: The clutch position switch is not adjustable.
  14. Pull out the speed control deactivation switch (if equipped) and brakelight switch plungers until they are fully extended. Measure the plunger length (dimension "A"). Speed control deactivation switch dimension "A" should be 0.94" (24 mm). Brakelight switch dimension "A" should be 0.83" (21 mm). See Figure.
  15. Install the pedal position switches.
    16. NOTE: The colors of the electrical connectors and switches are identical.
  16. Connect the electrical connectors to the pedal switches. To complete installation, reverse removal procedure.
Fig 1: Identifying Brake Pedal Switches
G00297546Courtesy of FORD MOTOR CO.
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