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Home >> Lincoln >> 2005 >> Aviator RWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brake Actuation >> Removal And Installation >> Brake Pedal and Bracket >> Installation

Brake Pedal and Bracket: Installation

  1. Position the brake pedal assembly in the vehicle.
  2. Position the instrument panel.
  3. Position the bulkhead electrical connector.
    • Tighten to 5 Nm (44 lb-in).
      Fig 1: Positioning Bulkhead Electrical Connector
      G03862087Courtesy of FORD MOTOR CO.
  4. Install the 4 side instrument panel to cowl support bolts.
    • Tighten to 30 Nm (22 lb-ft).
  5. Connect the steering intermediate shaft and install the pinch bolt.
    • Tighten to 30 Nm (22 lb-ft).
  6. Position the steering column opening cover panel and install the 2 screws.
  7. Install the top instrument panel-to-cowl and duct support bolts.
    1. Tighten to 9 Nm (80 lb-in).
    2. Tighten to 30 Nm (22 lb-ft).
      Fig 2: Installing Top Instrument Panel-To-Cowl And Duct Support Bolts
      G03862088Courtesy of FORD MOTOR CO.
  8. Install the defroster grille.
  9. Install the 2 windshield side garnish moldings.
  10. Position the 2 A-pillar passenger assist handles and install the 4 bolts.
    • Tighten to 11 Nm (8 lb-ft).
    • 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 retainer.
  13. Install the 2 door scuff plates.
  14. Position the 2 instrument support brackets and install the 4 nuts and 4 bolts.
    • Tighten to 9 Nm (80 lb-in).
  15. Install the instrument panel-to-cowl support bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 3: Installing Instrument Panel-To-Cowl Support Bolt
      G03862089Courtesy 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 adjustable accelerator 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 4 new brake booster nuts.
    • Tighten to 22 Nm (16 lb-ft).
  22. Connect the adjustable pedal motor electrical connector.
  23. Connect the accelerator pedal cable.
  24. Position the stoplamp switch, stoplamp switch bushing, spacers, and the brake booster rod on to the brake pedal.
  25. Install the redundant self-locking clip and cover.
    26. CAUTION: The brake pedal must be connected to the brake booster rod and in the at-rest position before installing the speed control deactivation switch, or the switch will be damaged.
  26. Install the speed control deactivation switch.
  27. Repower the supplemental restraint system (SRS). For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
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