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

Removal Procedure
  1. Disconnect the accelerator cable from the accelerator pedal. Refer to Accelerator Control Cable Replacement in Engine Controls - 2.2L (L61).
  2. Remove the retaining clip (1) and outer washer (2) from the brake pedal.

    3. Object Number: 1311217 Size: SH
  3. Disconnect the brake booster pushrod (3) from the brake pedal.
  4. Remove the inner washer (4) from the brake pedal.
  5. Remove the stop lamp switch from the brake pedal assembly. Refer to Stop Lamp Switch Replacement in Lighting Systems.
  6. Remove the cruise control release switch, if equipped, from the brake pedal assembly. Refer to Clutch Pedal Cruise Control Release Switch Replacement in Cruise Control.
  7. Release the electrical harness from the brake pedal assembly.

    8. Object Number: 188320 Size: SH
  8. Remove the brake booster mounting nuts (2).
  9. Remove the brake pedal assembly upper mounting nut.
  10. Remove the brake pedal assembly (1) from the vehicle.

Installation Procedure

    Object Number: 188320 Size: SH
  1. Install the brake pedal assembly (1) to the vehicle.
  2. Loosely install the brake pedal assembly upper mounting nut.

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

  3. Install the vacuum brake booster mounting nuts (2).

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

  4. Tighten the brake pedal assembly upper mounting nut.

    5. Tighten
    Tighten the nut to 27 N·m (20 lb in).


    Object Number: 1311217 Size: SH
  5. Secure the electrical harness to the brake pedal assembly.
  6. Install the stop lamp switch to the brake pedal assembly. Refer to Stop Lamp Switch Replacement in Lighting Systems.
  7. Install the cruise control release switch, if equipped, to the brake pedal assembly. Refer to Clutch Pedal Cruise Control Release Switch Replacement in Cruise Control.
  8. Install the inner washer (4) to the brake pedal.
  9. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal.
  10. Connect the brake pedal pushrod (3) to the brake pedal.
  11. Install the outer washer (2) and retaining clip (1) to the brake pedal.
  12. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
  13. Adjust the cruise control release switch, if equipped. Refer to Clutch Pedal Cruise Control Release Switch Adjustment in Cruise Control.
  14. Connect the accelerator cable to the accelerator pedal. Refer to Accelerator Control Cable Replacement in Engine Controls - 2.2L (L61).