GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Prizm 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.

    2. Object Number: 328462 Size: SH
  2. Remove the LH kick panel nut (1) and the LH kick panel (2).

    3. Object Number: 245084 Size: SH
  3. Remove the 2 screws and disconnect the hood release lever from the knee bolster.
  4. Remove the 2 bolts (3) that secure the knee bolster trim panel (1). Position the trim panel as necessary to gain access to the knee bolster.
  5. Remove the 2 bolts and the knee bolster.
  6. Remove the LH ventilation duct.

    7. Object Number: 240678 Size: MH
  7. Remove the following components:
    8. • The brake pedal return spring
    • The R-clip
    • The clevis pin
    • The wave washer
  8. Disconnect the brake light switch electrical connector.
  9. Remove the brake pedal bracket front bolt.
  10. Remove the brake pedal bracket mounting nuts.
  11. Remove the brake pedal and the bracket assembly.
  12. Remove the brake pedal shaft bolt and nut.
  13. Remove the brake pedal (3) from the bracket.
  14. Remove the brake pedal bushings.
  15. Remove the cover to the brake pedal.

Installation Procedure

    Object Number: 240678 Size: MH
  1. Install the cover to the brake pedal (3).
  2. Lubricate the brake pedal bushings using Lubriplate lubricant, GM P/N 12346293 (or equivalent). Use a lubricant that meets the requirements of NLGI 2 Category LB or GC-LB.
  3. Install the brake pedal bushings to the brake pedal.

    4. 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.

  4. Install the brake pedal to the bracket. Secure with the brake pedal shaft bolt and nut.

    5. Tighten
    Tighten the bolt and the nut to 20 N·m (14.75 lb in).

  5. Install the brake pedal and bracket assembly to the vehicle. Secure with the brake pedal bracket mounting nuts.

    6. Tighten
    Tighten the nuts to 10 N·m (89 lb in).

  6. Install the brake pedal bracket front bolt.

    7. Tighten
    Tighten the bolt to 20 N·m (14.75 lb ft).

  7. Connect the brake light switch electrical connector.
  8. Install the following components:
    9. • The wave washer
    • The clevis pin
    • The R-clip
    • The brake pedal return spring
  9. Install the LH ventilation duct.

    10. Object Number: 245084 Size: SH
  10. Install the knee bolster. Secure with 2 bolts.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  11. Install the knee bolster trim panel (1). Secure with 2 bolts (3).

    12. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  12. Connect the hood release lever. Secure with 2 screws.

    13. Object Number: 328462 Size: SH
  13. Install the LH kick panel (2). Secure with 1 nut (1).

    14. Tighten
    Tighten the nut to 5.4 N·m (48 lb in).

  14. Connect the negative battery cable.
  15. Inspect the Brake Pedal Travel. Refer to Brake Pedal Travel Measurement and Inspection .