Brake Pedal Assembly Replacement (Manual Transaxle)

Brake Pedal Assembly Replacement (Manual Transaxle)

Important:

* The brake pedal and clutch pedal are serviced as an assembly.

* A new brake and clutch pedal assembly includes disposable switch adjustment shims on the clutch arm switch contact areas and on the stop lamp switch contact area. Use these shims for switch adjustment as instructed then remove and discard the shims.

Removal Procedure

1. Remove the instrument panel (I/P) sound insulator.
2. Remove the intermediate steering shaft.




3. Remove the brake booster pushrod retaining clip (1) and bushing (2).
4. Loosen the 4 brake booster mounting nuts (3).
5. Loosen the 2 clutch pedal bracket mounting nuts (4).
6. Release the clutch master cylinder pushrod from the clutch pedal pivot pin.
7. Release the brake booster pushrod (5) from the brake pedal pivot pin.
8. Remove the 4 brake booster mounting nuts.
9. Remove the 2 clutch pedal bracket mounting nuts.




10. Remove the RH upper brake pedal bracket-to-steering column bracket bolt.




11. Remove the 2 LH upper brake pedal bracket-to-steering column bolts.




12. Lower the brake pedal assembly to access the brake pedal and clutch pedal switches.
13. Remove the stop lamp switch.
14. Remove the cruise release switch.
15. Remove the clutch pedal position switch from the pedal bracket.
16. Remove the clutch pedal engine start switch from the pedal bracket.
17. Remove the brake pedal and clutch pedal assembly.

Installation Procedure




1. Install the brake pedal and clutch pedal assembly to the vehicle.
2. Install the cruise release switch to the pedal bracket.
3. Install the stop lamp switch to the pedal bracket.
4. Install the clutch pedal engine start switch to the pedal bracket.
5. Install the clutch pedal position switch to the pedal bracket.
6. Move the brake pedal assembly to the installed position.




7. Loosely install the 2 LH upper brake pedal bracket-to-steering column bracket bolts.




8. Loosely install the RH upper brake pedal bracket-to-steering column bolt.




9. Loosely install the 4 brake booster mounting nuts (3).
10. Apply a thin coating of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the pushrod pin on the brake pedal and to the pushrod pin on the clutch pedal.
11. Connect the brake booster pushrod (5) to the brake pedal pivot pin.
12. Install the bushing (2) and retaining clip (1) to the brake pedal.
13. Loosely install the 2 clutch pedal bracket mounting nuts (4).
14. Secure the clutch master cylinder pushrod to the clutch pedal pivot pin.

Notice: Refer to Fastener Notice.

15. Tighten the vacuum brake booster mounting nuts.

Tighten the nuts to 22 N.m (16 lb ft).

16. Tighten the clutch pedal bracket mounting nuts.

Tighten the nuts to 10 N.m (89 lb in).

17. Tighten the LH and RH upper brake pedal bracket-to-steering column bolts.

Tighten the nuts to 25 N.m (18 lb ft).

18. Install the intermediate steering shaft.
19. Adjust the stop lamp switch.
20. Adjust the cruise control release switch.
21. Adjust the clutch pedal position switch.
22. Adjust the clutch pedal engine start switch.
23. Install the I/P sound insulator.