Brake systems · Brakes – mechanism · Assembly overview – brake pedal

Brake pedal, lefthand drive – assembly overview and fastening

The brake light switch is located on the brake master cylinder.

  • 1 Pedal cluster
  • 2 Self-locking hexagon nut, 25 Nm
    • Always renew after removing.
  • 3 Sleeve bearing
  • 4 Brake pedal
  • 5 Cap
  • 6 Ball socket
  • 7 Support
    • For ball head of brake booster plunger rod.
  • 8 Pivot pin
    • May be fitted only once because the tabs will break off when dismantled.
  • 9 Sleeve bearing

5.1.1 Separating brake pedal from brake booster

Special tools and workshop equipment required

  • Release tool - T 10159A-
  • First press brake pedal in direction of brake booster and hold.
  • 2 Plunger rod
  • 3 Retaining lugs
  • Insert release tool - T 10159A- and pull in direction of driver seat. When doing this, counter-hold on brake pedal. (At this stage the brake pedal must not be allowed to move backwards.) This action will press retaining lugs -3- of mounting off ball head of plunger rod -2-.

For the sake of clarity, separation of brake pedal from brake booster is shown with pedal cluster removed.

  • Pull release tool - T 10159A- and brake pedal together towards driver seat. (This action will pull the brake pedal off the ball head of the plunger rod).

5.1.2 Clipping brake pedal to brake booster

  • Hold ball head of plunger rod in front of mounting and push brake pedal in direction of brake booster, so that the ball head clicks into place.
  • Pull brake pedal briefly to ensure parts are engaged correctly.

5.1.3 Removing pedal cluster

  • Remove fuse box cover ⇒ General body repairs, interior; Rep. gr. 68; Compartments, covers and trims; Removing and installing fuse box cover.
  • Unbolt fuse box and lay to side.
  • Remove crash bar ⇒ Running gear, axles, steering; Rep. gr. 48.
  • Remove footwell vent ⇒ Heater, air conditioning system; Rep. gr. 80; Repairing heater; Removing vent.
  • Pull connector off accelerator pedal position sender.
  • Separate brake pedal from brake booster ⇒ 5.1.1 Separating brake pedal from brake booster.
  • Remove hexagon nuts -arrows- from pedal cluster.
  • Remove foot pedal cluster.

5.1.4 Installing pedal cluster

Install in reverse order.

5.1.5 Removing brake pedal

  • Turn pivot pin to left -movement arrow- using a 10 mm hexagon key; tabs -arrows 1- will then break off.
  • Pull pivot pin out.
  • Remove brake pedal.

5.1.6 Installing brake pedal

Install in reverse order.