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1-9
PEDAL GROUP DISASSEMBLY AND ASSEMBLY
ALL VEHICLES
Removing the Brake Pedal Assembly
1. Make sure key switch is off and that the Forward and Reverse Switch is in neutral, then disconnect bat-
tery or batteries as shown (In the Maintenance and Service Manual, see Figure 12-1, Page 12-2 for
gasoline vehicles, or Figure 22-5 or 22-6, Page 22-5 for electric vehicles). See CAUTION below.
2. Place chocks under the rear wheels and lift the front end of the vehicle with a chain hoist or floor jack.
Place jackstands under the front cross tube of the vehicle frame and lower the vehicle onto the jack-
stands. See WARNING below.
3. Remove the brake pedal assembly.
3.1. Disconnect the brake cables from the equalizer rod (26) (Figure 6-20, Page 26).
3.2. Remove the pedal return spring (27) from the equalizer rod (26) (Figure 6-20).
3.3. Remove the nuts (33), flat washers (25), bolts (28), and bearing blocks (23) (Figure 6-20).
3.4. Loosen the brake equalizer rod hex nut (24) five turns, then disconnect the rod (26) from the
pedal shaft (Figure 6-20).
3.5. Remove the nut (31) and brake stop (22) (Figure 6-20).
3.6. Lift the pedal assembly (6) up through the floorboard (Figure 6-20, Page 26).
Installing the Brake Pedal Assembly
1. Install the brake pedal assembly.
1.1. From the top side of the floorboard, insert the brake pedal weldment assembly (6) (Figure 6-20)
through the opening in the floor as shown (Figure 6-21, Page 27), and install the pedal stop (22)
(Figure 6-20) on the weldment.
1.2. Attach the equalizer rod (26) to the brake pedal weldment assembly (6) as shown (Figure 6-20).
1.3. Position and attach the brake pedal assembly and mounting blocks (23) to the vehicle frame as
shown. Tighten the bolts and nuts to 40-60 in.lbs. (4.5/7 N-m) (Figure 6-20). See NOTE below.
• DISCHARGE CONTROLLER ON POWERDRIVE SYSTEM 48 VEHICLES PER WARNINGS ON
PAGE 15.
• LIFT ONLY ONE END OF A VEHICLE AT A TIME. BEFORE LIFTING, LOCK THE BRAKES AND
CHOCK THE WHEELS THAT REMAIN ON THE FLOOR. USE A SUITABLE LIFTING DEVICE
(CHAIN HOIST OR HYDRAULIC FLOOR JACK) WITH 1000 LBS. (454 KG.) MINIMUM LIFTING
CAPACITY. DO NOT USE LIFTING DEVICE TO HOLD VEHICLE IN RAISED POSITION. ALWAYS
USE APPROVED JACKSTANDS OF PROPER WEIGHT CAPACITY TO SUPPORT THE VEHICLE.
• EACH HALF OF EACH MOUNTING BLOCK ASSEMBLY IS MARKED WITH AN A OR B. THE
HALVES MARKED A SHOULD BE ORIENTED TO THE TOP LEFT HAND AND BOTTOM RIGHT
HAND SIDES OF THE BRAKE PEDAL ASSEMBLY, AND THE HALVES MARKED B SHOULD BE
ORIENTED TO THE TOP RIGHT HAND SIDE AND BOTTOM LEFT HAND SIDE OF THE BRAKE
PEDAL ASSEMBLY (FIGURE 6-20, PAGE 26).
CAUTION
WARNING
NOTE
Summary of Contents for 1997 DS
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