Brake Pedal Assy: Service and Repair

REMOVAL PROCEDURE





1. Remove the cotter pin and the clevis pin from the brake booster pushrod (1).
2. Remove the pushrod clevis from the brake pedal.





3. Remove the brake pedal shaft bolt (1) and nut.

IMPORTANT: Note the location of the brake pedal return spring before removal.

4. Slide the brake pedal pivot shaft bolt out and remove the brake pedal from the vehicle.
5. Remove the brake pedal return spring (2) from the brake pedal (5).
6. Remove the two brake pedal bushings (3) from the brake pedal (5).
7. Remove the brake pedal spacer (4) from the brake pedal (5).
8. Remove the brake pedal pad (6) from the brake pedal (5).

INSTALLATION PROCEDURE





1. Install the brake pedal pad (6) to the brake pedal (5).
2. Lubricate the brake pedal spacer (4), bushing (3) and pivot shaft bolt (1) with chassis lubricant or the equivalent.
3. Install the brake pedal spacer (4) to the brake pedal (5).
4. Install the two brake pedal bushings (3) to the brake pedal (5).
5. Install the brake pedal return spring (2) to the brake pedal (5).
6. Install the brake pedal (5) to the vehicle.
7. Slide the brake pedal pivot shaft bolt (1) through the brake pedal pivot shaft. Secure the brake pedal pivot shaft bolt (1) with one nut. Do not tighten fully.

NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.






8. Install the brake pedal (2) to the brake booster push rod clevis(1). Secure the brake pedal with the clevis pin and the cotter pin.
^ Tighten the brake pedal pivot shaft bolt nut to 30 Nm (22 ft. lbs.).