Brake Pedal: Overhaul

HINT:

Refer to the procedures from the removal of the instrument panel register assy No.1 up until the removal of the instrument panel sub-assy w/ passenger airbag assy.

1. Remove the brake pedal return spring.
2. Remove the clip and brake master cylinder push rod pin.
3. Separate the push rod clevis from the brake pedal sub-assy.

Fig 1: Removing Master Cylinder Push Rod Clevis

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1. Disconnect the connector from the stop lamp switch assy.
2. Disconnect the connector from the brake pedal stroke sensor.
3. Remove the bolt from the instrument panel upper panel side.
   Fig 2: Removing Brake Pedal Support Sub-Assy

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4. Remove the 4 nuts and the brake pedal support sub-assy.
   Fig 3: Removing Nuts And Brake Pedal Support Sub-Assy

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1. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy from the brake pedal support sub-assy.

Fig 4: Removing Stop Lamp Switch Assy

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1. Remove the 2 bolts and separate the brake pedal stroke sensor from the brake pedal support sub-assy.

Fig 5: Removing Brake Pedal Stroke Sensor Assy

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1. Remove the nut from the brake pedal shaft.
2. Remove the brake pedal shaft and separate the brake pedal from the brake pedal support sub-assy.
3. Remove the 2 brake pedal bushes from the brake pedal sub-assy.
4. Remove the brake pedal shaft collar from the brake pedal shaft.

1. Apply lithium soap base glycol grease to the 2 new brake pedal bushes. Install the brake pedal bushes to the brake pedal sub-assy.
2. Install the brake pedal shaft collar to the brake pedal shaft.
3. Install the brake pedal to the brake pedal support with the brake pedal shaft and a nut.

   Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) 

1. Install the brake pedal stroke sensor to the brake pedal support sub-assy with the 2 bolts.

HINT:

Tighten the bolts when checking and adjusting the brake pedal height.

Fig 6: Installing Brake Pedal Stroke Sensor Assy

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1. Turn the stop lamp switch assy clockwise and install it to the brake pedal support sub-assy.

HINT:

Tighten the lock nut when checking and adjusting the brake pedal height.

Fig 7: Installing Stop Lamp Switch Assy

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1. Install the brake pedal support with the 4 nuts.

   Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

   Fig 8: Installing Brake Pedal Support Sub-Assy

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2. Install the brake pedal support from the instrument panel side with a bolt.

   Torque: 24 N.m (241 kgf.cm, 18 ft.lbf) 

3. Connect the connector to the stop lamp switch assy.
4. Connect the connector to the brake pedal stroke.

Fig 9: Connecting Connector To Brake Pedal Stroke

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1. Apply lithium soap base glycol grease to the circumference of the brake master cylinder push rod pin.
2. Install the push rod clevis to the brake pedal with the brake master cylinder push rod pin.
3. Install the clip and brake pedal return spring.

Fig 10: Installing Master Cylinder Push Rod Clevis

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