Removing brake pedal

NOTE:

For better accessibility, remove the lower cover under the steering column.

Installation Location:

Fig 1: Brake pedal and pin

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Fig 2: Dash lower cover and diagnostic socket

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1. Remove the lower cover. Refer to 70 22 19 Removing and installing cover under dashboard - as of MY 2003 (All Models) . At the diagnostic socket -arrow- just unclip the connector from the rear. See Fig 2.

2. Remove the lower cover (in knee area) and the deformation element. Refer to 70 19 19 Removing and installing trim under dashboard - as of MY 2003 (All Models) .

Fig 3: Clip for stop light switch

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3. Remove the holder for the stop light switch and unclip the connector -arrow- . Refer to 94 36 19 Removing and installing brake light switch - as of MY 2003 (All Models) . See Fig 3.

Fig 4: Lower cover holder

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4. Remove the holder -arrow- of the lower cover for the dashboard. See Fig 4.

Fig 5: Relay carrier tabs

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5. Remove relay carrier -arrows- . Refer to 97 90 19 Removing and installing relay carrier, plenum chamber E-box - as of MY 2003 (All Models) . See Fig 5.

Fig 6: Control units

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6. Remove both control units -arrow- , on the right side under the dashboard. Refer to 96 66 19 Removing and installing Kessy/immobiliser control unit - as of MY 2003 (All Models) . Refer to 97 10 19 Removing and installing vehicle electrical system control unit - as of MY 2003 (All Models) . See Fig 6.

7. Release the support (relay carrier/Kessy control unit/immobilizer/vehicle electrical system control unit) (left side and front engaged, right side screwed) and let them hang. In this way, the brake pedal shaft can be pushed out toward the center of the vehicle (cardan tunnel).

Fig 7: Unlocking tool T10189

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8. Disengage the brake pushrod from the brake pedal mounting using the unlocking tool T10189 . Observe the following procedure for this purpose:

Fig 8: Positioning unlocking tool T10189

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-1- - unlocking tool T10189 for brake pedal.

- Position the unlocking tool T10189 -1- so that the fork sits in correct position in the brake pedal mounting (in the inset, the fork in contact, view against the direction of travel). See Fig 8.

Fig 9: Unlocking tool T10189 force deflection point

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- Position the unlocking tool T10189 so that it is located in the right mold of the support and is perpendicular to the vehicle floor. Like this, the force deflection point (bending in the unlocking tool T10189) is precisely next to the screw head -arrow- . See Fig 9.

Fig 10: Releasing pushrod from brake pedal

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- When pressing forward on the lever (unlocking tool) (in direction of travel!), the brake pedal mounting is pressed apart and the ball of the pushrod is released. At the same time, pull the brake pedal to the rear (against the direction of travel!) and release the brake pedal from the pushrod.

Fig 11: Brake pedal released from the pushrod

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Fig 12: Brake pedal shaft (pin)

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9. Counter the brake pedal shaft (pin) -arrows- on the right side and slightly loosen to the left -(arrows)- . The nut remains on the brake pedal shaft to protect the thread. See Fig 12.

Fig 13: Retaining pin retainer

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10. Loosen the two upward running struts of the articulated strut and let them hang. To do this, remove the retainer on each retaining pin, remove the retaining pins, and let the struts hang down.

11. Using a hammer, force out the brake pedal shaft a few millimeters with short, heavy blows from left to right.

12. Place a screwdriver under the head of the brake pedal shaft (right side). Remove the nut, and lever out the brake pedal shaft carefully toward the center of the vehicle (cardan tunnel).

13. Carefully press out the brake pedal shaft so that the brake pedal can be removed.