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Home >> Ford >> 1996 >> Windstar V6-232 3.8L >> Repair and Diagnosis >> Brakes and Traction Control >> Brake Pedal Assy >> Service and Repair
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Brake Pedal Assy: Service and Repair






REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect stoplight switch electrical connector.
3. Remove the hairpin clip.
4. Remove the brake master cylinder push rod spacers, brake master cylinder push rod bushing, power brake booster input rod, and the stoplight switch from the brake pedal pin.
5. Remove one brake pedal shaft retainer from the brake pedal shaft.
6. Remove the brake and clutch pedal bushing and the brake pedal shaft from the brake pedal bracket.
7. Remove the brake pedal bushing, spring washer, and the brake pedal from the brake pedal bracket.
8. Disconnect accelerator cable from accelerator pedal and shaft.
9. Remove the two brake pedal bracket bolts and the four power brake booster nuts.
10. Remove the brake pedal bracket from the vehicle.

INSTALLATION
1. Position brake pedal bracket on power brake booster studs. Install four retaining nuts and two brake pedal bracket bolts. Tighten to 22-28 Nm (16-21 ft. lbs.).
2. Apply a light coating of engine oil to brake pedal shaft pin and bushings.
3. Install brake pedal bushings and spring washer on brake pedal.
4. Install two brake pedal bushings on brake pedal bracket. Position brake pedal on brake pedal bracket. Insert brake pedal shaft and install retainer.
5. Install one brake master cylinder push rod spacer on brake pedal pin.
6. Install the brake master cylinder push rod and the brake master cylinder push rod bushing on the brake pedal pin. Position the stoplight switch so that it straddles the push rod with the slot on the pedal pin and the switch outer frame hole just clearing the pin. Slide the stoplight switch upward onto the pin and push rod. Slide the assembly inboard toward the brake pedal arm. Install the outer brake master cylinder push rod spacer and the push rod retainer. Lock retainer securely.
7. Connect stoplight switch electrical connector.
8. Connect accelerator cable to accelerator pedal and shaft.

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