Ford 5W7Z-2455-AA
Pedal Assembly

All brake pedal assembly and accelerator pedal assembly maintenance requires the adjustable pedal system to receive an index calibration. Begin by plugging in the electrical connector to the adjustable pedal motor before removing the adjustable pedal motor drive cable from the brake pedal drive. Adjust the accelerator pedal all the way back while attaching the adjustable pedal motor drive cable to the adjustable brake pedal drive. Leave the adjustable brake pedal assembly before aligning its indexing marks using the adjustable pedal motor. Subsequently disconnect the adjustable pedal motor drive cable from this assembly. Put the accelerator pedal into a fully forward position before placing the adjustable pedal motor drive cable onto the adjustable brake pedal drive. The inspection should confirm that the brake and accelerator pedals are adjustable by at least 50 mm (2.0 inches) and the accelerator pedal should maintain a lower height of 50 mm (1.96 inches) than the brake pedal.

The service and repair of brake pedal assembly needs a battery ground cable disconnect as the first step. First remove the instrument panel close-out panel through the process of removing pushpins followed by turning the lamp counterclockwise. The service begins with removing the speed control deactivator switch and continues with removal of booster push rod retaining pin cover along with the retaining pin. First disconnect the brake pedal pin by removing the stoplight switch and washer followed by bushing and booster push rod. The brake pedal bracket bolt needs removal but must reach 30 Nm (22 ft. lbs.) when reinstalling it. Disengage the adjustable brake pedal drive cable attachment from the brake pedal and stoplight switch harness from the pedal bracket. The pinch bolt that connects the steering column lower yoke to the lower steering column shaft should be removed before discarding it but installing the new bolt with a torque of 28 Nm (21 ft. lbs.). Follow the removal of four brake pedal bracket nuts and detach the brake pedal and bracket before reinstalling them with 28 Nm (21 ft. lbs.) torque. An indexing step should always be performed on the adjustable pedal system whenever repair work takes place on the brake pedal assembly or the accelerator pedal assembly. Position the brake switch so that the closed opening faces the other direction from the brake pedal arm and the open side remains directed toward it. Reverse the removal steps while testing that the stoplights function correctly.

Service of the brake pedal assembly begins by disconnecting the battery ground cable followed by removing the instrument panel close-out panel with removal of pushpins and counterclockwise rotation of the lamp. First detach the speed control deactivator switch as well as the booster push rod retaining pin cover followed by the retaining pin itself. First disconnect the stoplight switch washer bushing together with booster push rod from the brake pedal pin before undoing the brake pedal bracket bolt while tightening this bolt to 30 Nm (22 ft. lbs.) when reinstalling. Disconnect the adjustable brake pedal drive cable from its position on the brake pedal assembly while also disconnecting the stoplight switch harness from facing the pedal bracket. Separate the lower steering column shaft from the steering column lower yoke by removing its pinch bolt for disposal because you will install a new pinch bolt and torque it to 28 Nm (21 ft. lbs.). Remove the brake pedal and bracket by taking out their four nuts while you will have to tighten all components to 28 Nm (21 ft. lbs.) upon reinstallation. Indexing of the adjustable pedal system must be performed during services requiring brake pedal assembly or accelerator pedal assembly maintenance. The brake switch should be placed with its closed hole facing away from the brake pedal arm and its open hole directed toward the pedal. Complete the procedure by retracting the dropped components and check the stoplight function operates correctly.

Disconnect it from the pedal bracket.