Brake Pedal Assembly Replacement

Removal Procedure

Brake Pedal Assembly Replacement — figure 1

1. Instrument Panel Lower Insulator Retainer (1) » Remove [2x]

Brake Pedal Assembly Replacement — figure 2

2. Instrument Panel Lower Trim Panel Insulator (1) » Remove

Brake Pedal Assembly Replacement — figure 3

3. Floor Front Air Outlet Duct Bolt (1) » Remove

Brake Pedal Assembly Replacement — figure 4

4. Floor Front Air Outlet Duct - Left Side (1) » Remove

Brake Pedal Assembly Replacement — figure 5

5. Disconnect the electrical connectors.
6. Release the retaining tabs.
7. Body Control Module (1) » Remove

Brake Pedal Assembly Replacement — figure 6

8. Wiring Harness Retainer (1) @ Brake Pedal » Remove [2x]
9. Brake Pedal Position Sensor Electrical Connector (2) » Disconnect

Brake Pedal Assembly Replacement — figure 7

10. Brake Pedal Position Sensor Bolt (1) » Remove
11. Brake Pedal Position Sensor (2) » Remove

Brake Pedal Assembly Replacement — figure 8

12. Brake Pedal Push Rod Bolt (1) » Remove

Brake Pedal Assembly Replacement — figure 9

13. Instrument Panel Tie Bar Bracket Nut (1) » Remove [2x]
14. Instrument Panel Tie Bar Bracket (2) » Remove

Brake Pedal Assembly Replacement — figure 10

15. Brake Pedal Nut (1) » Remove [5x]

Brake Pedal Assembly Replacement — figure 11

16. Radiator Surge Tank Bolt (1) » Remove

Brake Pedal Assembly Replacement — figure 12

17. Without disconnecting the hoses, remove the radiator surge tank and position aside. (1)

Brake Pedal Assembly Replacement — figure 13

18. Remove the brake master cylinder adapter nut (1) and pull the brake master cylinder (2) away from the fire wall to gain clearance for the removal of the brake pedal.

Brake Pedal Assembly Replacement — figure 14

19. Brake Pedal (1) » Remove Installation Procedure

20. Brake Pedal (1) » Install

Caution

Refer to Fastener Caution.

2. Brake Pedal Nut (1) » Install and tighten [5x] — Fastener Specifications

3. Instrument Panel Tie Bar Bracket (2) » Install

4. Instrument Panel Tie Bar Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

5. Brake Master Cylinder (2) » Install

6. Brake Master Cylinder Adapter Nut (2) » Install and tighten — Fastener Specifications

7. Radiator Surge Tank (1) » Install

8. Radiator Surge Tank Bolt (1) » Install and tighten — Fastener Specifications

9. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 9.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 9.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 9.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 9.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

10. Brake Pedal Push Rod Bolt (1) » Install and tighten — Fastener Specifications

11. Brake Pedal Position Sensor (2) » Install

12. Brake Pedal Position Sensor Bolt (1) » Install and tighten — Fastener Specifications

13. Wiring Harness Retainer (1) @ Brake Pedal » Install [2x]

14. Brake Pedal Position Sensor Electrical Connector (2) » Connect

15. Body Control Module (1) » Install

16. Secure the retaining tabs.

17. Connect the electrical connectors.

Warning

Upon installing the floor duct to the side of the HVAC case, it is necessary to verify duct opening is completely installed, surrounding the HVAC case outlet port. Failure to do so could result in the duct falling downward, with the potential to interfere with driver’s legs and gas/brake pedal operation.

18. Floor Front Air Outlet Duct - Left Side (1) » Install

19. Floor Front Air Outlet Duct Bolt (1) » Install and tighten — Fastener Specifications

20. Instrument Panel Lower Trim Panel Insulator (1) » Install

21. Instrument Panel Lower Insulator Retainer (1) » Install [2x]

22. Calibrate the brake pedal position sensor. Brake Pedal Position Sensor Calibration