- Lubricate brake pedal pivot pin and brake pedal bushings using Mopar Lubricate or an equivalent. Install brake pedal in mounting bracket. Install brake pedal pivot pin.
CAUTION:
When tightening brake pedal pivot pin attaching nut do not exceed torque specification. If torque specification is exceeded brake pedal can bind causing brakes to not fully release and brake light to remain on. After tightening and torquing pivot pin attaching nut check brake pedal to be sure it returns freely to released position.
- Install nut on brake pedal pivot pin. Tighten pivot pin attaching nut to 34 N.m (25 ft. lbs.). Install brake pedal and mounting bracket as an assembly back in vehicle using reverse sequence of its removal. Loosely install 2 nuts attaching top of brake pedal mounting bracket to instrument panel mounting bracket. DO NOT tighten nuts at this time, these nuts must be tightened after nuts mounting bracket to vacuum booster studs are tightened.
- Install nuts attaching pedal mounting bracket to vacuum booster mounting studs. Tighten mounting nuts to 23 N.m (200 INCH lbs.). Tighten 2 nuts attaching brake pedal mounting bracket to instrument panel bracket to 20 N.m (180 INCH lbs.). Install wiring harness junction connector bracket on right hand side mounting studs of vacuum booster. Tighten mounting nuts to 29 N.m (250 INCH lbs.). Using lubricate, or an equivalent, coat brake pedal pin where it contacts vacuum booster input rod.
NOTE:
When installing vacuum booster input rod on brake pedal pin input rod must be positioned as shown in illustration. See Figure
. The chamfer on vacuum booster input rod must facing brake pedal arm when installed on brake pedal pin. The retaining clip must be installed on flat side of vacuum booster input rod.
CAUTION:
When installing brake pedal pin on vacuum booster input rod, do not re-use old retaining clip.
- Install input rod for vacuum booster on brake pedal pin. See Figure
. Install a NEW retaining clip on brake pedal pin. See Figure
. The retaining clip must be installed on flat side of vacuum booster input rod. Install body controller on cowl panel. Install and securely tighten body controller mounting bolts. Install wiring harnesses on body controller. Be sure wiring harness connectors are securely locked into connectors on body controller.
NOTE:
Prior to installing stop lamp switch into bracket, plunger must be moved to its fully extended position.
- Hold stop lamp switch firmly in one hand. Using other hand, pull outward on plunger of stop lamp switch until it has reached out to its fully extended position. Connect wiring harness connector to stop lamp switch. Install stop lamp switch in brake pedal bracket. Stop lamp switch is installed using following procedure. Depress brake pedal as far down as possible. Then while holding brake pedal down, align index key on switch with slot in square hole of mounting bracket. When switch is fully installed in bracket, rotate stop lamp switch in a clockwise direction approximately 30 degrees.
CAUTION:
DO NOT use excessive force when pulling back on brake pedal to adjust stop lamp switch. If to much force is used, damage to stop lamp switch or striker can result.
- Gently pull back on brake pedal until it stops moving. This will cause switch plunger to ratchet back to its correct position. Install knee blocker panel on lower instrument panel. See Figure
. Install and securely tighten 2 screws attaching knee blocker panel to instrument panel. Connect remote ground cable for battery on ground post located on left shock tower.