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  #1  
Old 06-01-2011, 08:12 AM
TenSilver TenSilver is offline
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Default Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

I helped a friend make this repair and documented it for FRF members.

Test your pedal assembly by grasping it and trying to move it from side to side. Any side to side movement is wear in the brake pedal assembly.


Brake Pedal Assembly: How to replace.

This repair was performed on a standard cab 2002 Ranger Edge straight shift. Ranger years range from 1995 to 2003.

Possible failure symptoms are:
• Difficult to depress clutch pedal.
• Difficult to shift into gear.
• Brake lights fail to light when depressing the brake pedal or stay on after engine is turned off and releasing the brake pedal.
• Difficult or failure to start the engine after depressing the clutch pedal.


Precautions:
• Place vehicle on a level surface.
• Engage emergency brake and leave shifter in gear or place a chock a behind a wheel.
• Wear clothing you don’t mind getting dirty.
• Allow a minimum of 4 hours to perform this repair.


Tools required:
• 3/8 Drive ratchet.
• 3/8 Drive long and short extensions.
• 3/8 Drive universal.
• 13mm 3/8 drive standard socket.
• 13mm 3/8 drive deep well socket.
• Flat blade screw driver.


Parts Needed:
• New Brake Pedal Assembly from Ford parts. Ford part number 6L5Z 2455 BB. Cost is about $95.00 plus tax.


Procedure:
1. Remove driver’s seat. This allows you to lie on your back where the seat was to work under the dash more easily.
2. Unplug brake stop light switch by depressing the tab on the side of the plug. Refer to photo 1.




3. Remove pin clip which holds the brake light switch to the brake pedal by pushing pin out the top. I used the screw driver by putting the tip into the loop in the pin and pushing up. Pull the switch off the brake pin which will also remove the brake push rod and bushing. Refer to photo 2 and 3.






4. Unplug clutch pedal position switch by lifting the two ears outwards while pulling on plug. Refer to photo 1.
5. Un-snap clutch rod by pulling left it should snap right off. I used the screw driver to un-snap. Refer to photo 4.




6. Lift up the portion of the flooring covering 4 nuts holding the bottom of the brake pedal assembly. Item A on photo 1.
7. Remove 4 nuts from the bottom of the assembly using the 13mm deep well socket. Refer to photo 1 and photo 5.



8. Remove 2 bolts from the top of the assembly using the standard 13mm socket, universal and extensions. Not shown in photo 1, refer instead to photo 6.



9. Remove enough push pins, bolts and screws to gain access under the inner fender splash shield of the driver’s side wheel well. The clutch master cylinder is located under the brake booster.
10. Under the wheel well carefully twist the clutch master cylinder counter clockwise 45 degrees to unlock the master cylinder from the brake pedal assembly. Refer to item B on photo 1.
11. Inside pull out to un-snap the clutch push rod. The clutch master cylinder should now be free from the brake pedal assembly. Refer to photo 4.
12. Remove the brake pedal assembly by moving forward to clear the brake push rod. I had to have a helper to pull the brake booster forward just enough for the brake push rod to clear the assembly. We (helper and I) did not damage or bend the brake lines. Additional space for the booster push rod may be obtained by moving the clutch reservoir to one side.
13. Install new brake pedal assembly and reverse the removal procedure to complete the install.





Additional photos:
The brake pedal assembly is made of cast aluminum.
Old one on the left, new on the right. Notice added material at wear points.




Showing wear areas:





Conclusion:
You will have more travel in the clutch pedal and have a more firm brake pedal due to no movement in the pedals.

I would suggest you replace the brake light switch as it is a fairly inexpensive item. It wasn’t replaced on this truck.

Additional access may be gained by removing the bottom half of the dash under the steering wheel.

After removing the driver’s seat for this repair is still in a very tight and limited space area.

Let us know how you did if you perform this procedure. Let us know if you learned any short cuts to making this repair easier.
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Last edited by TenSilver; 06-01-2011 at 09:26 AM.
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  #2  
Old 06-01-2011, 08:15 AM
HazardousRanger HazardousRanger is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

id recomend puttng the pictures with the procedures...going back n forth is lame

otherwise. NICE WRITE UP
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  #3  
Old 06-01-2011, 09:21 AM
TenSilver TenSilver is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Will do. Thanks!
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  #4  
Old 06-01-2011, 09:28 AM
pooleo pooleo is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Fantastic! great write up. I wish I had a camera and "a" forum when I did my trans swap. That was a great experience with lots of info had I documented it. How was it for you getting that assembly out? it was a PITA when I took mine out to put in the clutch assembly!
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  #5  
Old 06-01-2011, 12:30 PM
TenSilver TenSilver is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

^^ Thanks! ^^
It was an interesting project for sure as the work was done under a tree in 95 degree heat. Lol!

The most difficult was getting the two top bolts shown in photo 6 and getting the brake assembly to clear the booster push rod. Interesting that once the two top bolts were out I could see light up through the vent holes near the wipers.

Still I think additional work room could have been had if we removed the bottom portion of the dash under the steering wheel.
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  #6  
Old 07-07-2011, 05:35 PM
Gibsonat994 Gibsonat994 is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

How did you unsnap the the master cylinder push rod out of the master cylinder? i tried pulling left like it says but nothing is happening. does it take a lot of strength? Because that little rod is bending a lot and i dont wanna break the end of in the master cylinder.

thanks
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  #7  
Old 11-02-2011, 04:15 AM
TenSilver TenSilver is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Wow! I don't know how I missed your question! Sorry about that!

Yes, It was pretty hard to get it to un-snap. I pulled and pushed it to the left and it poped right out.

Again sorry for the long delay in replying.
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  #8  
Old 12-04-2011, 09:00 AM
danger ranger 1999 danger ranger 1999 is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Thanks for the very helpful instructions. My only problem was that the clutch pedal rod definitely would not "unsnap" from the master cylinder. It was held in by a black spring steel capture clip which was behind a circlip. I pulled until the circlip came out along with a white plastic part from inside the clutch cylinder. I was able to pry the black spring steel piece out of the plastic part to release the clutch pedal rod. Installation required compressing the circlip and pushing it back in. I'll try to post a picture of the end of the rod with the circlip. It may be necessary to reach into the end of the clutch master cylinder with circlip pliers to release the clutch pedal rod.
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  #9  
Old 12-12-2011, 10:38 PM
El Bandito El Bandito is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Thanks for this write-up! I'll be performing this procedure this week on a 2004, and it seems like everything looks the same, except the brake switch clip looks different. I'll let you know how it goes, and hopefully I'll have some pictures to post. Thanks again, very helpful!
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  #10  
Old 01-18-2012, 01:44 PM
El Bandito El Bandito is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Success! The pushrod was a PITA to remove from the clutch master, but it's finally done. Looking at the pedal assembly, I can definitely see why there was so much play back and forth:



Thanks again for the write-up.
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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
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  #11  
Old 12-31-2013, 05:30 PM
Chris10 Chris10 is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

Hey guys, thanks so much for posting this. I wouldn't have known where to start without it. Who knew something with 6bolts/nuts could take so long to fix...

I've got to say though, I got a universal joint which made a lot of the ratcheting easier—except for one bolt on the top.
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  #12  
Old 05-14-2014, 01:33 PM
lurebuoy lurebuoy is offline
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Default Re: Replace Brake Pedal Assembly - 1995 to 2003 Manual Shift

I would like to add that I just performed this and the forum helped greatly. I certainly would have broken something or given up without it. However, one thing, I did not want to chance breaking the clutch push rod so I removed the switch surrounding it, allowing it to slip through the bracket. A link for removing the switch......http://www.makeonlinecollection.com/...ft-Pedal!.html

Last edited by lurebuoy; 05-14-2014 at 01:38 PM.
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