GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Aztek - FWD 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure
  1. Disable the SIR system. Refer to Disabling the SIR System in SIR.
  2. Remove the left side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.

    3. Object Number: 180291 Size: SH
  3. Remove the booster push rod (2) from the brake pedal (1).
  4. Disconnect the electrical connectors from the cruise control release if equipped and stop lamp switch.
  5. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.
  6. Remove the brake booster mounting nuts (3).

    7. Object Number: 180294 Size: SH
  7. Remove the brake pedal bracket mounting nuts (2).
  8. Remove the upper mounting nuts (1) from the brake pedal brace (4).
  9. Remove the brake pedal with the bracket (3).
  10. Remove the brake pedal brace (4) from the bracket.

    11. Object Number: 180295 Size: SH
  11. Remove the cruise control release switch (3), if equipped, and the stop lamp switch (1) from the brake pedal with the bracket (2).

Installation Procedure

    Object Number: 180295 Size: SH
  1. Install the cruise control release switch (3), if equipped, and the stop lamp switch (1) to the brake pedal with the bracket (2).

    2. Object Number: 180294 Size: SH

    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.

  2. Install the brake pedal brace (4) with the mounting nuts (1) to the bracket.

    3. Tighten
    Tighten the nuts (1) to 10 N·m (89 lb in).

  3. Install the brake pedal with the bracket (3).
  4. Install the upper mounting bolt for the brake pedal brace (4).

    5. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  5. Install the brake pedal bracket mounting nuts (2).

    6. Tighten
    Tighten the nuts (2) to 25 N·m (18 lb ft).


    Object Number: 180291 Size: SH
  6. Install the brake booster mounting nuts (3).

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

  7. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.
  8. Connect the electrical connectors to the cruise control release if equipped and stop lamp switch.
  9. Install the booster push rod (2) to the brake pedal (1).
  10. Adjust the stop lamp switch and the cruise control release switch if equipped. Refer to Stop Lamp Switch Adjustment .
  11. Install the left side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
  12. Enable the SIR system. Refer to Enabling the SIR System in SIR.