Installation - Chrysler PT Cruiser Service & Repair Manual

PT
PEDAL - WITH AUTOMATIC TRANSAXLE (Continued)
Fig. 77 Booster Mounting
1 - CLIP
2 - BOOSTER MOUNTING NUTS
3 - BOOSTER MOUNTING NUTS
(12) Remove the pivot shaft out the right side of
the bracket.
(13) Slide the pedal out of its bracket.
(14) The bushings can be removed from the pedal
by sliding them out each side of the pivot.

INSTALLATION

(1) Lubricate the brake pedal bushings with
Mopar Lubriplate or an equivalent.
(2) If removed, slide a bushing in each side of the
pedal until the bushing shoulder contacts the pedal
pivot.
(3) Install the brake pedal and bushings into the
pedal mounting bracket by sliding the pedal between
the sides of the bracket behind the brake lamp
switch mounting flange.
(4) Once the pedal bushings line up with the
mounting holes in the bracket, install the pivot shaft
through the pedal from the right side.
(5) Install the pivot shaft nut. Tighten the nut to a
torque of 34 N·m (25 ft. lbs.).
(6) Carefully install the brake pedal and bracket
assembly in the vehicle lining up the bracket with
the power brake booster mounting studs and the
studs on the instrument panel support.
(7) Install the two upper nuts securing the brake
pedal bracket to the instrument panel support.
Install the two nuts all the way, but do not tighten
them at this time.
(8) Install the four nuts securing the power brake
booster to the brake pedal bracket (Fig. 77). Tighten
the four nuts to a torque of 34 N·m (300 in. lbs.).
(9) Tighten the two upper nuts securing the brake
pedal bracket to the instrument panel support to a
torque of 34 N·m (300 in. lbs.).
(10) Install the power brake booster input rod on
the pin mounted on the side of the brake pedal.
Install a new retaining clip on the end of the pin
(Fig. 77). Do not reuse the old clip.
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(11) Mount and adjust the NEW brake lamp
switch using the following procedure:
• Install the switch in its bracket by aligning the
index tab on the switch with the slot in the mounting
bracket.
• When the switch is fully seated in its bracket,
rotate the switch clockwise approximately 30° to lock
the switch into place (Fig. 76).
• With the brake pedal in the fully released posi-
tion, move the lever on the back of the brake lamp
switch from the non-adjusted angle position to the
full vertical position (Fig. 78). This will adjust the
brake lamp switch to the vehicle.
Fig. 78 Switch Adjustment Lever
(12) Install the knee blocker.
(13) Install the silencer pad below the knee
blocker.
(14) Reconnect the battery negative terminal.
(15) Reinstall the air cleaner cover (two clips).
(16) Check the stop lamps to verify they are oper-
ating properly and not staying on when the pedal is
in the released position.
(17) Road test the vehicle to ensure proper opera-
tion of the brakes and speed control (if equipped).
BRAKES - BASE 5 - 43