Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement

Removal Procedure

1. Lower the steering column and position aside. Refer to Steering Column Replacement (Steering Column Replacement).




2. Disconnect the brake pedal position sensor (1) electrical connector.
3. Disconnect the clutch pedal position sensor (2) electrical connector.




4. Remove the brake pedal pushrod nut (1).
5. Disconnect the power brake booster pushrod from the brake pedal.




6. Remove the brake pedal pushrod washer (1).




7. Remove the clutch pedal bracket nuts (1).




8. Remove the vacuum brake booster nuts (1).




9. Using a flat bladed tool, carefully lever the clutch pedal pushrod (1) off the clutch pedal ball stud.
10. Remove the brake pedal pushrod (2) from the brake pedal pivot pin.




11. Remove the right upper brake pedal bracket bolt (1).




12. Remove the 2 left upper brake pedal bracket bolts (1).
13. Remove the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement (Instrument Panel Tie Bar Replacement).




14. Lower and remove the brake pedal and clutch pedal assembly (1).

Installation Procedure




1. Position the brake pedal and clutch pedal assembly (1) to the power brake booster studs.
2. Install the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement (Instrument Panel Tie Bar Replacement).




3. Loosely install the 2 left upper brake pedal bracket bolts (1).




4. Loosely install the right upper brake pedal bracket bolt (1).




5. Loosely install the vacuum brake booster nuts (1).




6. 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.
7. Secure the clutch pedal pushrod (1) to the clutch pedal ball stud.




8. Install the brake pedal pushrod washer (1).
9. Connect the brake pedal pushrod (2) to the brake pedal pivot pin.




10. Loosely install the clutch pedal bracket nuts (1).

Caution: Refer to Fastener Caution (Fastener Caution).

11. Tighten the vacuum brake booster nuts to 22 Nm (16 lb ft).
12. Tighten the clutch pedal bracket nuts to 10 Nm (89 lb in).
13. Tighten the LH and RH upper brake pedal bracket bolts to 25 Nm (18 lb ft).




14. Install the brake pedal pushrod nut (1) and tighten to 10 Nm (89 lb in).




15. Connect the brake pedal position sensor (1) electrical connector.
16. Connect the clutch pedal position sensor (2) electrical connector.
17. Install the steering column. Refer to Steering Column Replacement (Steering Column Replacement).

Warning

Replacement or reprogramming of the ECM, or replacement of the clutch pedal position sensor (CPPS) or clutch pedal requires that a CPPS learn procedure be performed. Failure to perform the CPPS learn procedure may result in personal injury or damage to the vehicle or its components if the vehicle is in gear and the starter motor is accidentally engaged.

18. Perform the clutch pedal position sensor learn procedure. Refer to Clutch Pedal Position Sensor Learn (Programming and Relearning).
19. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration ().