Brake pedal and pedal bracket (manual transmission) (Chassis / Hydraulic brake / Ford Focus 1 1998-2004)

Removal

All cars

1. Disconnect the lower section of the instrument panel.

1. Remove the screws.
2. Release the clamp.

2. Remove the lower section of the instrument panel.

Disconnect the data link connector (DLC).
Disconnect the footwell light plug connector (if equipped).

3. Disconnect the plug connectors from the pedal position switches.

1. Speed control system deactivation switch (if equipped).
2. Brake light switch
3. Clutch position switch.

4. Remove the pedal position switches.

1. Speed control system deactivation switch (green) (if equipped).
2. Brake light switch (gray).
3. Clutch position switch (red).

5. Disconnect the clutch master cylinder from the pedal bracket (the clutch position switch bracket is shown removed for clarity).

1.Remove the clamp.
2. Unscrew the bolts.

6. Disconnect the clutch master cylinder drive lever from the clutch pedal.

7. Remove the brake booster mounting nuts (for clarity, the clutch position switch bracket is shown removed).

8. Disconnect the brake booster pushrod from the brake pedal.

1. Depress the brake pedal.
2. Release the clamp.
3. Remove the brake booster push rod pin and discard it as no longer needed.

Right-hand drive vehicles manufactured up to 12/1998.

9. Disconnect the steering column shaft from the steering gear.

1.Loosen the top bolt.
2. Unscrew the lower bolt.
3. Move the sleeve up.

Right-hand drive vehicles manufactured from 12/1998 onwards.

10.

NOTE: Make sure the front wheels are pointing straight ahead.

Set the steering gear to the center position and lock it in this position.

11. Disconnect the steering column shaft from the steering gear.

1. Unscrew the bolt and discard it as no longer needed.
2. Disconnect the steering gear pinion shaft from the steering column.

Cars manufactured since 01.1999.

12. Remove the brake pedal return lever mounting bolt. Remove the air duct if necessary.

All cars

13. Remove the brake pedal bracket.

Installation

All cars

1.

NOTE: Make sure the brake pedal fits into the brake booster pushrod eye.

Install the brake pedal bracket.

2.

NOTE: Do not fully tighten the brake booster mounting nuts at this stage.

Install the brake booster mounting nuts (the clutch position switch bracket is shown removed for clarity).

Cars manufactured since 01.1999.

3.

NOTE: Do not fully tighten the brake pedal return arm mounting bolt at this stage.

Install the brake pedal return lever mounting bolt.

CAUTION: Make sure there is clearance between the brake pedal and the brake pedal return lever to allow freedom of movement.

Check the position of the brake pedal return lever and the brake pedal bracket.

All cars

5. Tighten the brake booster mounting nuts (for clarity, the clutch position switch bracket is shown removed).

Cars manufactured since 01.1999.

6. Tighten the brake pedal return lever mounting bolt. Install the air duct if necessary.

7. With the engine running, depress the brake pedal three times to ensure that the brake pedal moves freely and returns to the unapplied position.

Right-hand drive vehicles manufactured up to 12/1998.

8.

WARNING: Install a new steering column pinch bolt. Failure to follow this instruction may result in personal injury.

Connect the steering column shaft to the steering gear pinion shaft.

1.Move the sleeve down.
2. Tighten the bolts.

Right-hand drive vehicles manufactured from 12/1998 onwards.

9.

WARNING: Install a new steering column pinch bolt. Failure to follow this instruction may result in personal injury.

Connect the steering column shaft to the steering gear pinion shaft.

All cars

10. Connect the clutch master cylinder actuator lever to the clutch pedal.

11.

NOTE: Insert the clutch master cylinder into the holes in the pedal support bracket.

Attach the clutch master cylinder to the pedal bracket (the clutch position switch bracket is shown removed for clarity).

1.Install the bolts.
2. Install the clamp.

12.

CAUTION: Install a new brake booster push rod pin.

Install the brake booster push rod pin.

1. Depress the brake pedal.
2.Install the brake booster push rod pin.

13.

NOTE: The clutch position switch (red) is not adjustable.

Fully extend the plungers of the speed control deactivation switch (if equipped) and the brake light switch.

Measure the length of the plunger.
Speed control system deactivation switch (green) XX mm = 24 mm.
Brake light switch (grey) XX mm = 21 mm.

14.

CAUTION: When installing the switches, turn the brake light switch counterclockwise and the other switches clockwise. Failure to follow this instruction will result in the plungers sticking.

CAUTION: Make sure the switches are set correctly.

NOTE: The cruise control deactivation switch (if equipped) and brake light switch are automatically adjusted during installation.

NOTE: A slight noise and clicking sensation during installation of the cruise control deactivation switch (if equipped) and brake light switch is normal.

Set the pedal position switches.