Brake Pedal Assy: Service and Repair
WM 460519 Removing and installing brake pedal
Tools
Preliminary work
Preliminary work for removing and installing brake pedal
1. Move the driver's seat all the way back.
2. Remove dashboard bracket. -> 516819 Removing and installing dashboard bracket - section on "Removing" 516819 Removing and Installing Dashboard Support
Removing brake pedal
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
Component overview
1. Remove fastening screws -1- for crash support -2-.
Crash support
Remove crash support.
2. Disengage the brake push rod from the brake pedal mounting using the release tool T10189. Observe the following procedure for this purpose:
Release tool T10189
Pressing out brake pedal (shown as an example)
2.1. Position the release tool T10189 -1- so that the fork is at the correct position in the brake pedal mounting (in the inset, the fork is engaged, view looking away from direction of travel).
2.2. Position the release tool T10189 so that it is located in the right mould of the support and is perpendicular to the vehicle floor. Here the deflection point of force (bend in the release tool T10189) is right next to the screw head -arrow-.
Levering out brake pedal (shown as an example)
2.3. When pressing forward on the lever (release tool) (in direction of travel!), the brake pedal mounting is pressed apart and the ball of the push rod is released. At the same time, pull the brake pedal to the rear (away from direction of travel!) and release the brake pedal from the push rod.
Releasing push rod from brake pedal (shown as an example)
Brake pedal released from push rod (shown as an example)
3. Pull out the lock -1- at the left of the brake pedal shaft -2- ( -arrow- ).
Brake pedal lock
4. Using a hammer, press out the brake pedal shaft a few millimetres with short, heavy blows from left to right.
5. Insert a screwdriver under the head of the brake pedal shaft (right side). Carefully lever the brake pedal shaft -1- towards the centre of the vehicle (cardan tunnel) and out of the brake pedal -2- ( -arrow- ).
Pressing out brake pedal shaft
Installing brake pedal
Information
- 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 -> 46 Tightening torques for brake mechanics - Refer to Specifications.
- Tightening torque for brake pedal shaft (pin): 15 +/- 2 ftlb.
1. Insert the brake pedal into the vehicle.
2. Press the brake pedal shaft -1- fully into the brake pedal -1- ( -arrow- ).
Pressing in brake pedal shaft
3. When sliding in the brake pedal shaft -1- , ensure that the cut-out -2- on the brake pedal shaft fits into the guide -3- on the holder -4-.
Positioning brake pedal shaft
4. Slide the lock -1- at the left onto the brake pedal shaft -2- ( -arrow- ).
Fitting brake pedal lock
5. Position the brake pedal -1- on the push rod -2- for the brake booster.
Brake pedal on push rod
6. Press the brake pedal -1- through fully -arrow- until the push rod -2- clicks into place in the holder -3- on the brake pedal.
Fitting brake pedal
7. Position crash support -2- on the brake pedal.
Crash support
Fit fastening screw -1- for crash support -2-. -> 4X00IN Tightening torques for brake mechanism 4X00IN Tightening torques for brake mechanics
Subsequent work
Subsequent work for removing and installing brake pedal
1. Fit dashboard bracket. -> 516819 Removing and installing dashboard bracket - section on "Installing" 516819 Removing and Installing Dashboard Support