Hyundai Tucson: Brake System / Brake Pedal Repair procedures
| 1. |
Remove the crash pad lower panel.
(Refer to Body - "Crash Pad") |
| 2. |
Pull down steering column shaft after removing bolts and nuts. |
| 3. |
Disconnect the stop lamp switch connector (A). 
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| 4. |
Remove the brake pedal member mounting nuts (B).
Tightening torque:
16.7 ~ 25.5 N.m (1.7 ~ 2.6 kgf.m, 12.34 ~ 18.8 lb-ft)
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| 5. |
Remove the snap pin (A) and clevis pin (B). 
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| 6. |
Remove the brake pedal member assembly mounting nuts and then remove the brake pedal assembly.
Tightening torque:
16.7 ~ 25.5 N.m (1.7 ~2.6 kgf.m, 12.3 ~ 18.8 lb-ft)
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| 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. 
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| Brake Pedal Height and Free Play |
| 1. |
Disconnect the stop lamp switch connector (A) and loosen the stop lamp switch lock nut. 
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| 2. |
Adjust the brake pedal height (A) as illustration below.
Pedal height (A) : 165 mm (6.50 in)
Full stroke : 135 mm (5.31 in)
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| 3. |
Adjust the stop lamp switch clearance (B) and brake pedal free play.
Stop lamp clearance (B) : 1.5 ~ 2.0 mm (0.06 ~ 0.08 in)
Pedal free play : 3.0 ~ 8.0 mm (0.12 ~ 0.31 in)
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| 4. |
Connect the stop lamp switch connector. |
| 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. |
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| 2. |
Adjust the brake pedal height and free play. |
| 3. |
Check the brake pedal operation. |
Components
1. Cowl bracket2. Brake pedal member assembly3. Stop lamp switch4. Return spring5. Brake pedal stopper6. Clevis pin7. Snap pin8. Brake pedal
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Components
1. Guide rod bolt2. Bleed screw3. Caliper bracket 4. Caliper body5. Inner pad shim6. Brake pad7. Pad retainer
...
Brake Pedal Components and Components Location
Front Disc Brake Components and Components Location