Brake Pedal - Clunk/Rattle Noise
File In Section: 05 - BrakesBulletin No.: 01-05-22-001
Date: January, 2001
TECHNICAL
Subject:
Clunk, Rattle Noise from Front of Vehicle
(Replace Brake Pedal Assembly)
Models:
1997-2001 Chevrolet Malibu
1997-1999 Oldsmobile Cutlass
1999-2001 Oldsmobile Alero
1999-2001 Pontiac Grand Am
with Automatic Transmission
Built Prior to the VIN Breakpoints shown.
Condition
Some customers may comment on a rattle or clunk type noise coming from the underbody or front suspension.
Cause
The brake pedal pivot pin bushing may cause this condition.
Correction
Diagnose condition prior to replacing the brake pedal assembly by putting light side pressure on the brake pedal with your foot and applying the brakes. If the noise is no longer present, replace the existing brake pedal assembly with a new assembly, P/N 22672398. If the noise is still present, re-evaluate the condition using diagnostic information in the appropriate Service Manual. Follow the service procedure listed below to replace the brake pedal assembly.
1. Remove left sound insulator panel.
2. Depress the accelerator control cable (1) tangs from the pedal lever assembly.
3. Remove the accelerator control cable from the pedal lever assembly.
4. Disconnect the brake pedal pushrod (1) from the brake pedal (2).
5. Disconnect the electrical connector from the stop lamp switch.
6. Remove the stop tamp switch (5) from the brake pedal bracket by grasping the switch and turning it go degrees counter clockwise while pulling toward the rear of the vehicle.
7. Disconnect the electrical connector from the cruise release switch.
8. Remove the cruise release switch (3) from the brake pedal bracket by grasping the switch and turning it 90 degrees counter clockwise while pulling toward the rear of the vehicle.
9. Disconnect the electrical harness from the brake pedal bracket.
10. Remove the upper (1) and the lower (2) mounting nuts from the brake pedal assembly.
11. Remove the brake pedal assembly.
12. Install the brake pedal assembly into position.
13. Install the upper and the lower mounting nuts to the brake pedal assembly.
Tighten
Tighten the mounting nuts to 27 Nm (20 lb ft).
14. Connect the brake pedal pushrod to the brake pedal.
15. Connect the electrical harness to the brake pedal bracket.
16. Insert the stop lamp switch and cruise release switch into their containers until the switch body is seated on the retainer.
17. Connect the electrical connectors to the stop lamp switch and cruise release switch.
Important:
Adjust the stop lamp switch and cruise release switch at the same time. The adjustment procedures for the switches are identical.
18. Adjust the stop lamp switch and cruise release switch.
18.1. Pull the brake pedal (4) upward against the internal pedal stop.
18.2. Turn the switch 90 degrees clockwise in order to lock the switch into position.
19. Install the accelerator control cable to the pedal lever assembly. Ensure the tangs are fully expanded and seated.
20. Slip the accelerator control cable through the slot in the rod of the accelerator pedal and install the retainer in the rod. Ensure the retainer is seated.
21. Check for proper operation of stop lamps and cruise control.
22. Install the left sound insulator panel.
Parts Information
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty use the table.
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