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

Removal Procedure
  1. Remove the left side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
  2. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.
  3. Disable the SIR system. Refer to Disabling the SIR System in SIR.
  4. Disconnect the electrical connectors from the cruise control release and stoplamp switches.
  5. Remove the booster push rod Retain clip and washer (2) from the brake pedal assembly.

    6. Object Number: 180291 Size: SH
  6. Remove the booster push rod (2) from the brake pedal (1).
  7. Remove the brake booster mounting nuts (3).

    8. Object Number: 180294 Size: SH
  8. Remove the brake pedal assembly mounting nuts (2).
  9. Remove the brake pedal assembly with the bracket (3).
  10. Remove the brake pedal assembly from the vehicle.

    11. Object Number: 180295 Size: SH
  11. Remove the cruise control release switch (3) and the stop lamp switch (1) from the brake pedal assembly .

Installation Procedure

    Object Number: 180295 Size: SH
  1. Install the cruise control release switch (3) and the stop lamp switch (1) to the brake pedal assembly (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. Position the brake pedal brace (4) to the brake pedal assembly and install the brace mounting nuts

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

  3. Install the brake pedal assembly with the brace (3) to the vehicle.
  4. Install the the brake pedal brace (4) upper mounting bolt.

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

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