Removing Brake Pedal

Fig 1: Identifying Brake Pedal Installation Position

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Information 

• The pictures shown in this document may differ from the original  .

1. Secure the clutch power spring assembly. (Only for manual transmission) 
   1. 1.1. Pull off rubber sleeve on the plenum panel -arrow-  .
      Fig 2: Pulling Rubber Sleeve

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   2. 1.2. Press the clutch pedal -1-  slightly -arrow A-  until the clutch power spring axle -2-  is visible through the bore.
      Fig 3: Securing Clutch Power Spring Assembly

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   3. 1.3. Fit a suitable cotter pin -3-  into the bore on the clutch power spring axle -arrow B-  .
2. Disengage clutch master cylinder. (Only for manual transmission) 
   1. 2.1. Release retaining clip for push rod -1-  in the clutch pedal -2-  using a pliers T10005  (-arrows A-  ) and pull it out slightly -arrow B-  .
      Fig 4: Disengaging Push Rod

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   2. 2.2. Turn the clutch master cylinder anti-clockwise by approx. 60° -arrow A-  .
      Fig 5: Removing Clutch Master Cylinder

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   3. 2.3. Pull the clutch master cylinder out slightly -arrow B-  .
3. Disengage push rod for brake booster.
   Fig 6: Pressing Out Push Rod

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   1. 3.1. Release tool T40024 -1-  must be guided in from below in front of the ball joint on the push rod -2-  .
   2. 3.2. Press the release tool together -arrows A-  and separate the ball joint from the securing clip -3-  (-arrow B-  ).
4. Disconnect pedals.
   1. 4.1. Unscrew fastening screws -arrows-  above the brake booster.
      Fig 7: Locating Pedals Screws

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   2. 4.2. Unscrew fastening screws -arrows-  from the brake booster.
      Fig 8: Locating Brake Booster Pedals Screws

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   3. 4.3. Screw off inner fastening nuts -arrows-  .
      Fig 9: Locating Pedals Inner Fastening Nuts

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   4. 4.4. Pull the pedals out somewhat and press down slightly.
5. Remove brake pedal.
   1. 5.1. Pull out the lock -1-  at the left of the brake pedal shaft -2-  (-arrow-  ).
      Fig 10: Removing Brake Pedal Lock

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   2. 5.2. Using a hammer, press the brake pedal shaft out by a few millimeters with short blows from left to right.
   3. 5.3. Insert a screwdriver under the head of the brake pedal shaft -1-  (right side). Carefully lever the brake pedal shaft -1-  towards the center of the vehicle (heater/air-conditioning unit) and out of the brake pedal -2-  . -arrow A- 
      Fig 11: Removing Brake Pedal

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   4. 5.4. Press the brake pedal -2-  out in a downward direction -arrow B-  .