Hyundai Sonata: Brake Pedal. Repair procedures - Brake System - Brake SystemHyundai Sonata: Brake Pedal. Repair procedures

Removal

1.
Remove the crash pad lower panel. (Refer to the Body group- crash pad).
2.
Pull down steering column shaft after removing bolts and nuts. (Refer to the steering group - Steering columm & shaft)
3.
Disconnect the stop lamp switch connector (A).

4.
Remove the brake pedal member mounting nut (B).

Tightening torque:
9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)

5.
Remove the snap pin (A) and clevis pin (B).

6.
Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.

Tightening torque:
9.8 ~ 14.7 N.m (1.0 ~ 1.5 kgf.m, 7.2 ~ 10.8 lb-ft)


Inspection

1.
Check the bushing for wear.
2.
Check the brake pedal for bending or twisting.
3.
Check the brake pedal return spring for damage.
4.
Check the stop lamp switch.
(1)
Connect a circuit tester to the connector of stop lamp switch, and check whether or not there is continuity when the plunger of the stop lamp switch is pushed in and when it is released.
(2)
The stop lamp switch is in good condition if there is no continuity when plunger(A) is pushed.


Adjustment

Stop lamp switch clearance adjustment
If the gap between stop lamp switch and bracket is not 1.0 ~ 2.0mm(0.04~ 0.08in), conform to below.
1.
Disconnect the stop lamp switch connector (B).

2.
Release locking plate by pushing the hooks (B) carefully, and then pull the locking plate (A) as indicated by the arrow (C).

3.
Turn stop lamp switch 45° counterclockwise and remove it.

4.
Fix the brake pedal arm and insert fully the stop lamp switch as hiding contact part.

5.
After inserting, turn the stop switch (A) 45° clockwise, and then assemble locking plate (B) by pushing.

6.
Confirm the gap between stop lamp switch and bracket.

Stop lamp clearance:
1.0~2.0mm(0.04~ 0.08in.)

7.
Connect the stop lamp switch connector.

Installation

1.
Installation is the reverse of removal.
Before installing the pin, apply the grease to the clevis pin.
Use a new snap pin whenever installing.
2.
Adjust the brake pedal height and free play.
3.
Check the brake pedal operation.

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