LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2003 >> Focus SVT, 4D Hatchback >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes & Drum Brakes >> Removal & Installation >> Brake Pedal >> Removal & Installation (2003-04 M/T)

Removal & Installation (2003-04 M/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 harness connectors from the speed control deactivation switch (if equipped), brakelight switch and clutch position switch. See Figure.
  4. Remove speed control deactivation switch (Green), if equipped, brakelight switch (Gray) and clutch position switch (Red). See Figure.
  5. Disconnect the clutch master cylinder from the pedal bracket (clutch position switch bracket shown removed for clarity). Remove the clip. Remove the bolts. See Fig 1.
  6. Detach the clutch master cylinder actuating rod from the clutch pedal. See Fig 2.
  7. Remove the brake booster retaining nuts. See Fig 3.
  8. Detach 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. See Figure.
  9. Remove the brake pedal retractor arm retaining bolt. See Fig 4. Remove the air duct, if necessary.
  10. Remove the brake pedal bracket.
  11. 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.
  12. 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 Fig 5. Ensure there is clearance between the brake pedal and the brake pedal retractor to allow free movement.
  13. Tighten the brake booster retaining nuts.
  14. Tighten the brake pedal retractor arm retaining bolt.
  15. 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.
    16. NOTE: When installing the pedal switches, ensure switches are installed correctly. The brakelight switch (Gray) rotates counterclockwise to install and the clutch pedal position switch (Red) and 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.
  16. 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 Fig 6.
  17. Install the pedal position switches.
    18. NOTE: The colors of the electrical connectors and switches are identical.
  18. Connect the electrical connectors to the pedal switches. To complete installation, reverse removal procedure.
Fig 1: Locating Pedal Bracket Clip & Bolts
G00294702Courtesy of FORD MOTOR CO.
Fig 2: Disconnecting Clutch Master Cylinder Actuating Rod
G00294703Courtesy of FORD MOTOR CO.
Fig 3: Removing Brake Booster Retaining Nuts
G00297544Courtesy of FORD MOTOR CO.
Fig 4: Identifying Brake Pedal Retractor Arm Retaining Bolt
G00297545Courtesy of FORD MOTOR CO.
Fig 5: Aligning Brake Pedal Retractor Arm To Brake Pedal Bracket
G00297548Courtesy of FORD MOTOR CO.
Fig 6: Measuring Plunger Length
G00297547Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals