FAW Brake Pedal And Clutch Pedal Assembly: An Expert Analysis of 22 Critical Components

Welcome to this expert technical analysis of the FAW Brake Pedal And Clutch Pedal Assembly (Assembly 541). This is the complete, multi-part driver control interface for the FAW Jiefang CA4251P66K24T1A3E5 6×4 diesel semi-trailer tractor. This assembly is the critical link translating driver intentions into mechanical, pneumatic, and hydraulic actions.

The FAW Brake Pedal And Clutch Pedal Assembly is a complex, firewall-mounted unit. Its “logic” is threefold: it provides the mechanical levers for the driver’s feet (‘Brake pedal assy’ and ‘Clutch pedal assy’), it provides the “master” actuation for the hydraulic clutch (‘Clutch master cylinder assy’), and it provides the proportional “logic” for the air brake system (‘Brake valve & connecting head assy’).

This in-depth guide is an essential resource for professional technicians and fleet managers. We will deconstruct the entire FAW Brake Pedal And Clutch Pedal Assembly into its 22 serviceable components, including the main ‘Pedal bracket’, the ‘Pedal shaft’, the ‘Clutch switch assembly’, the ‘Stop light switch assembly’, and all associated hardware. Understanding this FAW Brake Pedal And Clutch Pedal Assembly is key to diagnosing many braking and shifting issues.

Core Structure: The ‘Pedal Bracket’ (3504031-91W)

The foundation of the entire FAW Brake Pedal And Clutch Pedal Assembly is the ‘Pedal bracket’ (3504031-91W). This is the heavy-duty, fabricated steel “skeleton” that bolts directly to the truck’s firewall. Its function is to provide a rigid, un-flexing mount for all the other components.

This bracket must be incredibly strong, as it has to withstand the full force of a “panic stop,” where the driver may exert hundreds of pounds of force on the brake pedal. Any flex in this bracket would translate to a “spongy” or “soft” pedal feel, reducing braking confidence.

This bracket is also the “logic” hub for the pivot system. It is precision-bored to accept the ‘Pedal shaft’ (3504032-50A). This single, hardened steel shaft acts as the main pivot axle for *both* the ‘Brake pedal assy’ and the ‘Clutch pedal assy’. The pedals pivot on this shaft via the ‘Bushing-pedal shaft’ (3504061-50A), which is a low-friction, replaceable wear component. The entire FAW Brake Pedal And Clutch Pedal Assembly is built upon this bracket.

The “Brake Logic”: Valve (3514010-50A) and Pedal (3504070-91W)

The “Brake Pedal” side of the FAW Brake Pedal And Clutch Pedal Assembly is a pneumatic control system. The ‘Brake pedal assy’ (3504070-91W) is the steel lever the driver’s foot presses. When pressed, this pedal’s primary job is to actuate the ‘Brake valve & connecting head assy’ (3514010-50A).

This valve is the “logic” of the air brake system. It is a **proportional valve**. It takes the high-pressure (120+ PSI) air from the truck’s main tanks and “meters” it out to the brake lines based on *how far* the driver has pressed the pedal.

• **Pedal 20% pressed:** Valve releases ~30 PSI to the brakes.
• **Pedal 100% pressed:** Valve releases the full 120 PSI for a panic stop.

This proportional logic is what allows the driver to “feather” the brakes. The ‘Return spring-brake pedal’ (3504036-50A) is a heavy-duty spring that ensures the pedal (and thus the valve) returns to the “zero” position instantly when the driver’s foot is removed, releasing the brakes. A failed or “sticky” FAW Brake Pedal And Clutch Pedal Assembly‘s brake valve is a critical safety failure.

The “Clutch Logic”: Master Cylinder (1602110-76W) and Pedal (1602020-76W)

The “Clutch Pedal” side of the FAW Brake Pedal And Clutch Pedal Assembly is a hydraulic control system. The ‘Clutch pedal assy’ (1602020-76W) is the steel lever for the driver’s left foot. When pressed, it pivots on the ‘Pedal shaft’ and pushes a rod.

This rod actuates the ‘Clutch master cylinder assy’ (1602110-76W). This is the “logic” of the clutch control. It is a small, hydraulic pump. It takes the driver’s mechanical push and converts it into high-pressure *hydraulic* fluid (brake fluid). This fluid is fed from the ‘Clutch master cylinder oil cup assy’ (1602100-50A), which is the plastic fluid reservoir.

This hydraulic pressure is then sent *out* of the cab, through a hose (see Assembly 139), and into the “Clutch Booster.” The booster then uses this small hydraulic signal to control a large *pneumatic* (air) cylinder, which provides the “power assist” to disengage the heavy-duty clutch. A failure of this master cylinder, or air in the line, will result in a “dead” pedal that goes to the floor, leaving the driver unable to shift. This part of the FAW Brake Pedal And Clutch Pedal Assembly is essential for operating the vehicle.

The Electronic Logic: Switches (3720010-A01 & 3754030-76W)

The FAW Brake Pedal And Clutch Pedal Assembly is not just mechanical; it is also an electronic “input” system for the truck’s ECU (Engine Control Unit).

**’Stop light switch assembly’ (3720010-A01):** This is the brake light switch. It is a simple plunger switch that is activated by the ‘Brake pedal assy’ (3504070-91W) as soon as it is pressed. Its “logic” is to instantly turn on the truck’s (and trailer’s) brake lights. A failure of this switch is a major safety hazard.

**’Clutch switch assembly’ (3754030-76W):** This is the clutch pedal sensor, mounted on the ‘Clutch switch bracket assy’ (1602250-76W). This switch’s “logic” is vital for the truck’s computer. It sends a signal to the ECU the moment the driver presses the clutch. The ECU uses this signal to:

• Instantly disengage the Cruise Control.
• Instantly disengage the Engine Brake / Jake Brake.
• (On some models) Enable the “start-interlock” (preventing the engine from starting unless the clutch is pressed).
• (On automated models) Signal the engine to briefly cut fuel for a smoother, faster shift.

Seals, Pins, and Fasteners

The entire FAW Brake Pedal And Clutch Pedal Assembly is designed for a high-vibration, high-use environment. The ‘Sealing gasket-pedal bracket’ (3504033-50A) is the large foam or rubber gasket that seals the entire ‘Pedal bracket’ (3504031-91W) against the cab firewall, blocking noise, heat, and fumes.

The system is held together by a series of fail-safe pins and high-tensile fasteners. The ‘Cotter pin’ (Q436150) and ‘Cotter pin’ (Q5002016) are used on the ‘Clevis pin’ (Q5100825) and ‘Threaded pivot-brake pedal’ (3504062-50A). This “castle-nut-and-pin” logic is a positive mechanical lock, ensuring these critical pivot points can *never* vibrate apart.

‘Hex head flange lock nuts’ (CQ32608) and various ‘Combination bolts’ (CQ1460620) and ‘Hex head bolts’ (CQ1500620) with ‘Spring gaskets’ (Q40306, Q40308) are used to secure all the components to the main bracket. Every piece of hardware in the FAW Brake Pedal And Clutch Pedal Assembly is a safety-critical, vibration-proof fastener.

FAW Brake Pedal And Clutch Pedal Assembly Parts List

The following table provides the complete, detailed breakdown of all 22 components identified in the ‘Brake Pedal And Clutch Pedal Assembly’ (541) diagram for the FAW CA4251P66K24T1A3E5 tractor.

Technical Specifications and Assembly Context

The specifications for the FAW Brake Pedal And Clutch Pedal Assembly are defined by its dual-function “logic” as both a pneumatic brake controller and a hydraulic clutch master. This FAW Brake Pedal And Clutch Pedal Assembly is a safety-critical driver interface.