GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure
  1. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.
  2. Remove the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
  3. Remove the electrical connector from the brake apply sensor.
  4. Remove the steering column assembly from the vehicle. Refer to Steering Column Replacement in Steering Wheel and Column.

    5. Object Number: 1301945 Size: SH
  5. Disconnect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) from the brake pedal pin (4).

    6. Object Number: 1241592 Size: SH
  6. Remove the 2 brake pedal assembly to cowl mounting nuts.

    7. Object Number: 1242219 Size: SH
  7. Remove the 3 brake pedal assembly to instrument panel (I/P) carrier bolts.
  8. Remove the brake pedal assembly from the vehicle.

Installation Procedure

    Object Number: 1242219 Size: SH
  1. Install the brake pedal assembly to the vehicle.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the 3 brake pedal assembly to I/P carrier bolts.

    3. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).


    Object Number: 1241592 Size: SH
  3. Install the 2 brake pedal assembly to cowl mounting nuts.

    4. Tighten
    Tighten the nuts to 15 N·m (11 lb ft).


    Object Number: 1301945 Size: SH
  4. Connect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) to the brake pedal pin (4).
  5. Install the steering column assembly to the vehicle. Refer to Steering Column Replacement in Steering Wheel and Column.
  6. Install the electrical connector to the brake apply sensor.
  7. Install the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
  8. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.
  9. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration Description and Operation in Lighting Systems.