Cougar/XR7 V8-4.6L VIN W (1997)
Brake Pedal Assy: Service and Repair
REMOVAL
1. Disconnect battery ground cable.
2. Disconnect the stoplight switch wire connector from the stoplight switch.
3. Loosen the three pedal support bracket retaining nuts at the dash panel.
4. Loosen pedal support bracket to instrument panel retaining bolt.
5. Remove the push rod retainer and brake master cylinder push rod spacer.
6. Slide the stoplight switch outboard along the brake pedal pin just far enough for the outer hole of the switch frame to clear the pin. Remove the
stoplight switch by sliding it off the pin.
7. Remove the brake master cylinder push rod bushing from the push rod.
8. Remove brake pedal.
INSTALLATION
1. Apply a coating of clean engine oil to the brake master cylinder push rod bushing. Locate brake master cylinder push rod bushings and brake
master cylinder push rod spacer in the brake pedal hub.
2. Position brake pedal onto brake booster studs that come through the dash panel. Make sure the brake pedal can swing freely while not being too
loose side-to-side. If there is too much free play side-to-side, increase locknut torque. The brake pedal must continue to swing freely. Replace
brake pedal if it cannot swing freely.
3. Install the master cylinder push rod and the brake master cylinder push rod bushing on the brake pedal pin. The large diameter portion of brake
master cylinder push rod bushing must not be between the push rod and pedal arm.
4. Position the stoplight switch so it straddles the push rod with the slot on the pedal pin and the switch outer frame hole just clearing the pin.
5. Slide the stoplight switch onto the pin and push rod. Slide the assembly toward the brake pedal arm.
6. Install the brake master cylinder push rod spacer and the push rod retainer. Lock the retainer securely.
7. Tighten the three pedal support retaining nuts to 21-29 Nm (16-21 ft. lbs.). Tighten pedal support bracket to instrument panel retaining bolt to
27-34 Nm (20-25 ft. lbs.).
8. Connect the stoplight switch wire to the stoplight switch.
9. Connect the battery ground cable.
