Testing and Inspection for Free Height Measurement - Cougar/XR7 V8-46L VIN W
Brake Pedal Assy: Testing and Inspection
With Drum Brakes
NOTE: Measure the brake pedal free height AND travel with the engine running for full power brake operation and the parking brake fully released.
PREPARATION
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Block wheels.
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Apply and release park brake. If park brake does not fully release, diagnose and repair parking brake before continuing.
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"START" engine for full power brake operation.
NOTE: "A" Dimension to be measured to sheet metal from center of pad on the accelerator pedal side of the brake pedal pad.
FREE HEIGHT
1. Insert a slender, sharp-pointed prod through the floor carpet and sound deadener to the floor metal.
2. Measure the distance from floor pan to the center on top of the brake pedal pad.
3. If the position of the brake pedal is not 174-200 mm (7-8 inch), check the brake pedal for missing, worn or damaged bushings or loose retaining
bolts and replace if required.
4. If the brake pedal free height is still out of specification, check the brake pedal, power brake booster or brake master cylinder to be sure the correct
parts are installed. Replace any incorrect, worn or damaged parts.
NOTE: "B" Dimension to be measured parallel to the vertical center line of the steering column with a 111.2 N (25 lb) load applied to the center line of
the brake pedal pad.
PEDAL TRAVEL
1. Install the Rotunda Car Gauge or equivalent on the brake pedal.
2. Hook a steel measuring tape to the brake pedal.
3. Measure and record the distance from the brake pedal free height position to the reference point, which is at the six o'clock position on the steering
wheel rim.
4. With the steel tape still hooked to the brake pedal,
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Apply a 111 N (25 lb) load to the center of the brake pedal.
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Maintain the brake pedal load.
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Measure the distance from the brake pedal to the fixed reference point on the steering wheel rim parallel to the centerline of the steering
column.
5. The difference between the brake pedal free height measurement and the depressed pedal measurement under a 111 N (25 lb) load should be 76.2
mm (3 inches) maximum.
6. If the brake pedal travel is more than the maximum dimension specification, attempt to adjust as follows:
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Make several forward then reverse stops.
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Move the vehicle in REVERSE and FORWARD for approximately 10 feet. Then apply the brakes, holding the brake pedal down until the