Brake Pedal Replacement Replacement

1. Remove the hoses from the hydraulic booster.
2. Remove the two nuts that attach the master cylinder to the hydraulic booster.
3. Remove the master cylinder and support it.



4. Remove the pushrod retainer.
5. Remove the retaining clip and washer.
6. Remove the hydraulic booster pushrod.



7. Remove the four nuts that attach the hydraulic booster to the support bracket.
8. Remove the hydraulic booster assembly.

1. Install the hydraulic booster assembly.
2. Install the four nuts that attach the hydraulic booster assembly to the support bracket.

Tighten
Tighten the nuts to 29 N·m (20 lb ft).




3. Install the hydraulic booster pushrod.
4. Install the washer and retaining clip.
5. Install the pushrod retainer.



6. Install the master cylinder.
7. Install the two nuts that attach the master cylinder to the hydraulic booster.

Tighten
Tighten the nuts to 27 N·m (20 lb ft).

8. Install the hoses.

Tighten
Tighten the hose fittings to 29 N·m (21 lb ft).

9. Bleed the hydraulic booster. Refer to Bleeding the Hydraulic Booster System.

Brake Pedal Replacement Linkage

1. Remove the brake pushrod from the brake pedal.
2. Remove the main pivot bolt and nut.
3. Remove the brake pedal rod lever assembly.
4. Remove the bushings and spacer.



5. Remove the bolt, nut, washer, and strap.
6. Remove the retainers.
7. Remove the washers.
8. Remove the brake pedal pushrod and the booster pushrod.
9. Remove the wave washers.
10. Inspect all parts for wear, damage, and corrosion. Replace as needed.

1. Lubricate the pivot points with Lubriplate (GM P/N 1050109) or equivalent.
2. Install the wave washers.
3. Install the brake pedal pushrod and the booster pushrod.
4. Install the washers.
5. Install the retainers.
6. Install the bolt, nut, washer, and strap.

Tighten
Tighten the nut to 33 N·m (24 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




7. Install the bushings and spacer.
8. Install the brake pedal rod lever assembly.

Insert the rod into the booster and push it until it seats.

9. Install the main pivot bolt and nut.

Tighten
Tighten the nut to 55 N·m (41 lb ft).

10. Install the brake pushrod to the brake pedal.