GM Service Manual Online
For 1990-2009 cars only

Brake Pedal Assembly Replacement RHD

Removal Procedure

    Caution: Refer to Brake Fluid Caution in the Preface section.

    Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

    Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

    Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

  1. Remove the instrument panel lower trim panel assembly. Refer to Knee Bolster Replacement.
  2. Remove the instrument panel lower right trim plate assembly. Refer to Instrument Panel Insulator Panel Replacement - Right Side.
  3. Remove the instrument panel lower trim panel retainer. Refer to Instrument Panel Retainer Replacement.
  4. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement.
  5. Remove the vacuum hose and check valve from the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement.
  6. Remove the brake pedal position sensor. Refer to Stop Lamp Switch Replacement.

  7. Object Number: 1943698  Size: SH
  8. Remove the brake pedal pushrod retaining clip (1), washer (2) and the brake pedal pushrod (3) from the brake pedal (4).

  9. Object Number: 1943705  Size: SH
  10. Remove the vacuum brake booster to brake pedal support bracket retaining nuts (1).
  11. Important: From the engine compartment, pull the vacuum brake booster forward to release the four studs from the bulkhead and brake pedal support bracket.

  12. Remove the vacuum brake booster from the vehicle.

  13. Object Number: 1943707  Size: SH
  14. Remove the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).
  15. Important: Lower the brake pedal assembly rear end first to aid in removal.

  16. Remove the brake pedal assembly from under the instrument panel.

Installation Procedure

    Caution: Refer to Brake Fluid Caution in the Preface section.

    Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

    Notice: Refer to Adding Fluid to the Brake System Notice in the Preface section.

    Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

    Important: Raise the brake pedal assembly front end first to aid in installation.

  1. Install the brake pedal assembly to the instrument panel crossmember.

  2. Object Number: 1943707  Size: SH
  3. Install the two brake pedal bracket assembly to instrument panel crossmember retaining bolts (1).
  4. DO NOT fully tighten at this stage.

    Important: Make sure the vacuum brake booster's four studs are correctly located in the bulkhead and brake pedal support bracket.

  5. With the aid of an assistant install the vacuum brake booster from the engine compartment.
  6. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1943705  Size: SH
  7. Install the vacuum brake booster to brake pedal support bracket retaining nuts (1).
  8. Tighten
    Tighten the nuts to 22 Nm (16 lb ft).


    Object Number: 1943698  Size: SH
  9. Install the push rod (3), washer (2) and retaining clip (1) to the brake pedal assembly (4).

  10. Object Number: 1943707  Size: SH
  11. Tighten the two brake pedal bracket assembly to cross car beam retaining bolts (1).
  12. Tighten
    Tighten the bolts to 23 Nm (17 lb ft).

  13. Install the brake pedal position sensor. Refer to Stop Lamp Switch Replacement.
  14. Install the vacuum hose and check valve to the vacuum brake booster. Refer to Power Brake Booster Inlet Hose Replacement.
  15. Install the master cylinder. Refer to Master Cylinder Replacement.
  16. Bleed the braking system. Refer to Hydraulic Brake System Bleeding.
  17. Install the instrument panel lower trim panel retainer. Refer to Instrument Panel Insulator Panel Replacement - Right Side.
  18. Install the instrument panel lower trim panel assembly. Refer to Knee Bolster Replacement.
  19. Road test the vehicle to inspect correct brake, stop lamp and cruise control operation.