Brake Pedal Assy: Service and Repair

Removing and installing brake pedal
Tools





Preliminary work
1. Move the driver's seat back.
2. Remove the lower cover. At the diagnostic socket just unclip the connector from the rear.

Removing brake pedal

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









1. Remove the lower cover. At the diagnostic socket -arrow- just unclip the connector from the rear.
2. Remove the lower cover (in knee area) and the deformation element.





3. Remove the holder for the stop light switch and unclip the connector -arrow-.





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





5. Remove relay carrier -arrows-.





6. Remove both control units -arrow-, on the right side under the dashboard.
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).





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





- 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).





- Position the unlocking tool T10189 so that it is located in the right mould 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-.





- 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.









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.





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.

Installing brake pedal
Installation is in reverse order.

Note:
^ Do not grease or spray the brake pedal shaft (pin).
^ For vehicles with automatic transmission a spacer tube is used instead of the clutch pedal.
^ Use new lock nuts.
^ Observe correct tightening torques.
^ Tightening torque for brake pedal shaft (pin): 15 +/- 2 ft lb.

Subsequent work
Remove the lower cover.