Brake Pedal Assy: Service and Repair

Brake Pedal Assembly Replacement

Removal Procedure

1. Remove the IP carrier assembly, to gain access to the brake pedal assembly to cowl mounting nuts. Refer to Instrument Panel (I/P) Carder Replacement in Instrument Panel, Gages and Console.
2. Remove the accelerator cable from the brake pedal bracket assembly. Refer to Accelerator Controls Cable Replacement in Engine Controls 3.8L.
3. Remove the steering column support mounting nuts. Refer to Steering Column Replacement in Steering Wheel Column.
4. Lower the steering column and support.
5. Disconnect the electrical connectors (3) from the stop lamp/ABS/shift lock switch (2).
6. Remove the stoplamp/ABS/shift lock switch. Refer to Stop Lamp Switch Replacement in Lighting Systems.
7. Disconnect the electrical connector from the TCC/cruise control release switch.
8. Remove the TCC/cruise control release switch from the brake pedal assembly. Refer to Torque Converter Clutch/Cruise Control Release Switch Replacement in Automatic Transaxle-4T65-E.
9. Remove the vacuum brake pushrod retainer (3) from the brake pedal clevis pin.
10. Remove the foam spacer (2) from the brake pedal clevis pin.
11. Disconnect the vacuum brake booster push rod (1) from the brake pedal.
12. Remove the brake pedal assembly mounting nuts (2, 3) from the booster studs (2, 3).
13. Remove the brake pedal assembly mounting to cowl stud nuts (1).
4. Remove the brake pedal assembly.

Installation Procedure

1. Install the brake pedal assembly into position on the brake booster and cowl studs.

Notice: Refer to Fastener Notice in Cautions and Notices.

2. Install the brake pedal assembly to brake booster mounting nuts (2, 3).
Tighten
Tighten the brake pedal assembly to booster stud mounting nuts (2, 3) to 23 N.m (17 lb ft).
3. Install the brake pedal assembly to cowl stud mounting nuts.
Tighten
Tighten the brake pedal assembly to cowl mounting nuts (1) to 16 N.m (12 lb ft).
4. Apply a small amount of lubricant, GM P/N 12346293 or equivalent, to the clevis pin of the brake pedal.
5. Connect the vacuum brake booster pushrod (1) to the brake pedal clevis pin.
6. Install the foam spacer (2) to the brake pedal clevis pin.
7. Install the retainer (3) to the brake pedal clevis pin.
8. Install the TCC/cruise control release switch to the brake pedal assembly. Refer to Torque Converter Clutch/Cruise Control Release Switch Replacement in Automatic Transaxle-4T65-E.
9. Install the stop lamp/ABS/shift lock switch. Refer to Stop Lamp Switch Replacement in Lighting Systems.
10. Connect the electrical connectors (3) to the stop lamp/ABS/shift lock switch (2).
11. Connect the electrical connector to the TCC/cruise control release switch.
12. Install the steering column. Refer to Steering Column Replacement in Steering Wheel Column.
13. Install the accelerator cable to the brake pedal bracket assembly. Refer to Accelerator Controls Cable Replacement in Engine Controls - 3.8L.
14. Install the IP assembly. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel, Gages and Console.