Brake Pedal Assy: Service and Repair

REMOVAL - NON-ADJUSTABLE PEDAL





1. Remove retainer clip that holds booster to pedal pin.
2. Remove nut from pedal shaft.
3. Slide pedal shaft out and remove brake pedal.





4. Remove pedal bushings if they are to be replaced.

REMOVAL - ADJUSTABLE PEDALS

NOTE: If possible put the pedals in the full forward position.

1. Disconnect the negative battery cable.
2. Remove the cluster bezel.
3. Remove the steering column opening cover.
4. Disconnect the module electrical connector.
5. Remove the brake light switch.
6. Disconnect the booster rod clip.
7. Disconnect the accelerator cable from the pedal.
8. Lock the steering wheel into place.





9. Remove the lower steering shaft pinch bolt.
10. Separate the lower shaft coupler and push forward).





11. Remove the two pedal bracket upper nuts.
12. Remove the brake booster nuts.





13. Remove the accelerator pedal nuts.
14. Remove the ICU mounting bracket nuts and bolts and move the ICU and booster forward this will allow enough clearance to remove the adjustable pedal bracket from over the booster push rod.
15. Remove the pedal from the vehicle.
16. Transfer the module if needed.

INSTALLATION - NON-ADJUSTABLE PEDAL
1. Lubricate bushings, pedal shaft and pedal pin with Mopar multi-mileage grease.
2. Install bushings into pedal.
3. Position pedal in bracket and install pedal shaft in support and through pedal.
4. Install new nut on pedal shaft and tighten to 27 Nm (20 ft. lbs.).

NOTE: Pedal shaft nut should not be reused.

5. Install booster push rod on pedal pin and install retainer clip on pedal pin.
6. Check and adjust stop lamp switch if necessary.

INSTALLATION - ADJUSTABLE PEDALS
1. Install the pedal to the vehicle.
2. Reposition the ICU and booster, Install the ICU mounting bracket nuts and bolts.
3. Install the brake booster nuts. Tighten to 28 Nm ( 21 ft. lbs.)..
4. Install the pedal bracket upper nuts. Tighten to 12 Nm ( 9 ft. lbs.)..
5. Install the accelerator pedal nuts. Tighten to 28 Nm ( 21 ft. lbs.)..
6. Install the lower steering shaft coupler over the shaft.
7. Install the lower steering shaft pinch bolt.
8. Unlock the steering wheel.
9. Reconnect the accelerator cable to the pedal.
10. Reconnect the booster rod clip.
11. Install the brake light switch.
12. Reconnect the module electrical connector.
13. Install the steering column opening cover.
14. Install the cluster bezel.
15. Reconnect the negative battery cable.