Ford Fusion: Hydraulic Brake Actuation / Brake Pedal and Bracket. Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp switch. This switch must be removed with the brake pedal in the at-rest position. The switch plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the switch when the plunger is extended (during pedal apply) will result in damage to the switch.

   Remove the stoplamp switch.
   Refer to: Stoplamp Switch (417-01 Exterior Lighting, Removal and Installation).
   

1. Remove the accelerator pedal.
   Refer to: Accelerator Pedal (310-02 Acceleration Control, Removal and Installation).
   

1. Detach the steering column opening cover clips and lower the cover.
   

1. Remove the screws and the lower steering column shroud.
   

1. Remove the screw, the pin-type retainer and the HVAC duct.
   

1. NOTICE: Do not allow the steering column shaft to rotate while disconnected from the gear or damage to the clockspring may occur. If there is evidence that the steering column shaft has rotated, remove and recenter the clockspring. Refer to Section 501-20B.

   Secure the steering wheel using a steering wheel holding device.
   

1.   WARNING: Do not reuse steering column shaft bolts. This may result in fastener failure and steering column shaft detachment or loss of steering control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

   Remove and discard the steering column shaft bolt.
   

1. Compress the tabs and remove the clevis pin. Discard the pin.
   

1. Remove the screws, detach the wiring retainers and position the wiring aside.
   

1. NOTE: Have an assistant pull the brake booster and master cylinder assembly forward to allow the brake pedal and bracket to clear the brake booster studs during removal and installation.

   Remove the nuts, bolts and the brake pedal and bracket. Discard the nuts and bolts.
   Torque: 17 lb.ft (23 Nm)

Installation

1. To install, reverse the removal procedure.