GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 Transmission/Transaxle 🢒 Clutch 🢒 Clutch Pedal Replacement

Removal Procedure

    Object Number: 891499 Size: SH
  1. Remove the clutch pedal retainer from the front of the clutch pedal assembly.

    2. Object Number: 889965 Size: SH
  2. Disconnect the clutch pedal position switch (2) from the clutch bracket.

    3. Object Number: 878807 Size: SH
  3. Remove the clutch pedal pivot nut.

    4. Object Number: 878809 Size: SH
  4. Disconnect the clutch master cylinder from the clutch pedal assembly.
  5. Remove the clutch bracket to front of dash nuts.
  6. Lower the steering column opening trim cover. Disconnect the 4 steering column electrical connectors and remove the steering column mounting bolts. Refer to Steering Column Replacement.

    7. Move the steering column enough to have clearance to remove the clutch pedal and bracket assembly.

  7. Remove the clutch pedal and bracket assembly.

    8. Object Number: 891500 Size: SH
  8. Remove the clutch pedal pivot bolt (1) and retainer (2).
  9. Remove the clutch pedal.
  10. Secure the clutch pedal and return spring and remove the clutch pedal pivot bolt.

    11. Object Number: 891681 Size: SH
  11. Remove the clutch pedal (3), return spring (2), and pivot bushings (1).

Installation Procedure

    Object Number: 891681 Size: SH
  1. Install the clutch pedal (3), return spring (2), and pivot bushings (1).

    2. Object Number: 891500 Size: SH
  2. Secure the clutch pedal and return spring and install the clutch pedal pivot bolt (1) and retainer (2).

    3. Object Number: 878809 Size: SH
  3. Install the clutch pedal and bracket assembly.

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

  4. Install the clutch pedal bracket to front of dash nuts.

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

  5. Connect the steering column 4 electrical connectors. Install the steering column mounting bolts and steering column opening trim cover. Refer to Steering Column Replacement.
  6. Connect the clutch master cylinder to the clutch pedal assembly.

    7. Object Number: 878807 Size: SH
  7. Install the clutch pedal pivot nut.

    8. Tighten
    Tighten the nut to 10 N·m (89 lb in).


    Object Number: 889965 Size: SH
  8. Connect the clutch pedal position switch (2) to the clutch pedal bracket.

    9. Object Number: 891499 Size: SH
  9. Install the clutch pedal retainer to the front of the clutch pedal assembly.

    10. Object Number: 889965 Size: SH
  10. Connect the clutch start switch (2) to the clutch pedal bracket.

    11. Object Number: 1547861 Size: SH
  11. If a new clutch pedal assembly was installed, perform the following steps to adjust the pedal position switch:
    12. 11.1. A 3/32 inch or 2 mm drill bit can be used as a gage tool for the proper adjustment of the CPP switch. Insert and seat the 3/32 inch or 2 mm drill bit through the slot in the top of the clutch pedal assembly.
    11.2. Install the CPP switch (1) to the clutch pedal assembly.
    11.3. While holding the pedal in the fully released position, press the switch (1) toward the pedal until the barrel of the switch touches the drill bit on the pedal assembly.
    11.4. Rotate the switch (1) clockwise to secure.
    11.5. Remove the drill bit.
    11.6. Connect the electrical connector (2) to the CPP switch (1).

    Object Number: 1547859 Size: SH
  12. Remove the shipping clip (1) from the new pedal assembly.
  13. Adjust the clutch start switch. Refer to Clutch Pedal Engine Start Switch Replacement.