Brake Pedal Assembly Replacement (J90, J95, J96, JH6, Two-mode Hybrid)

Brake Pedal Assembly Replacement (J90, J95, J96, JH6, Two-mode Hybrid)

Removal Procedure

1. Block the drive wheels.




2. Disconnect the brake pedal position sensor electrical connector.

3. Remove the brake pedal position sensor bolt (1).




4. Remove the brake pedal position sensor (1).




5. Remove the power brake booster pushrod retaining clip bolt (1).




6. Remove the power brake booster pushrod retaining clip (1).

7. Disconnect the power brake booster pushrod.




8. Unhook the brake pedal return assist spring (1) from the brake pedal arm to release the spring tension.




9. Remove the brake pedal pivot nut (1).




10. Remove the brake pedal pivot bolt (1).




11. Remove the brake pedal (1).




12. Remove the brake pedal return assist spring (1).




13. Remove the brake pedal return assist spring bushing (1).

14. Inspect the brake pedal return assist spring and bushing for wear or damage and replace, if necessary.

Installation Procedure

1. Apply a thin coat of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the following areas:

* The bushing side of the brake pedal pivot hub between the brake pedal arm and the pivot hub flange.

* The inner diameter of the brake pedal assist spring bushing and both sides of the bushing flange.

* The inner diameter of the brake pedal return assist spring.

* The 90 degree end and the hook end of the brake pedal return assist spring.




2. Install the brake pedal return assist spring bushing (1) to the brake pedal pivot hub by slightly spreading the bushing and positioning the bushing flange against the brake pedal arm.




3. Install the brake pedal return assist spring (1) to the brake pedal pivot hub with the hook end of the spring against the driver side edge of the brake pedal arm.

4. Apply a thin coat of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the brake pedal pivot bolt shoulder.




5. With the brake pedal return assist spring resting on the driver side of the brake pedal arm, install the brake pedal (1).




6. Install the brake pedal pivot bolt (1).

7. Clean the brake pedal pivot bolt threads of any grease after the bolt is inserted through the brake pedal pivot.

8. Apply medium strength threadlocker-blue GM P/N 12345382 (Canadian P/N 10953489) to the brake pedal pivot bolt threads.





Caution: Refer to Fastener Caution Fastener Caution.

9. While holding the brake pedal pivot bolt stationary, install the brake pedal pivot nut (1) and tighten to 26 Nm (19 lb ft).




10. Loosely assemble a tie strap to the hook end of the brake pedal return assist spring.

11. Using the tie strap, pull and hook the brake pedal assist return spring (1) into position against the leading edge of the brake pedal arm.

12. Remove and discard the tie strap.

13. With the power brake booster pushrod disconnected, inspect the brake pedal return assist spring function by pressing the brake pedal until it is parallel with the accelerator pedal and releasing.

14. Ensure the brake pedal returns to the at rest position.

15. Apply a thin coat of high temperature lubricant, GM P/N 12345996 (Canadian P/N 10953501) to the brake pedal pivot pin.

16. Connect the power brake booster pushrod.




17. Install the power brake booster pushrod retaining clip (1).

18. Rotate the power brake booster retaining clip 360 degrees to ensure the clip is fully engaged in the brake pedal pivot pin groove.




19. Install the power brake booster pushrod retaining clip bolt (1) and tighten to 10 Nm (89 lb in).




20. Install the brake pedal position sensor (1).




21. Install the brake pedal position sensor bolt (1).

22. Connect the brake pedal position sensor electrical connector.

23. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .