GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure
  1. Release the electric power steering (EPS) wiring harness from the brake pedal bracket.
  2. Release the accelerator pedal position (APP) sensor jumper harness from the brake pedal bracket.

    3. Object Number: 927716 Size: SH
  3. Disconnect the electrical connector from the APP sensor.

    4. Object Number: 878810 Size: SH
  4. Loosen the brake booster mounting nuts.
  5. Remove the retaining clip (4) and washer (3) from the brake pedal.
  6. Release the brake booster pushrod (2) from the brake pedal.
  7. Remove the brake booster mounting nuts.
  8. Remove the brake pedal bracket-to-steering column bracket bolt (1).

    9. Object Number: 878813 Size: SH
  9. Lower the brake pedal assembly to improve access for switch removal.
  10. Remove the stop lamp switch from the pedal bracket. Refer to Stop Lamp Switch Replacement .
  11. Remove the cruise control release switch, if equipped, from the pedal bracket. Refer to Cruise Control Release Switch Replacement .
  12. Remove the brake pedal assembly, with the accelerator pedal assembly from the vehicle.

    13. Object Number: 898158 Size: SH
  13. Remove the accelerator pedal mounting bolts and remove the pedal assembly.

Installation Procedure

    Object Number: 898158 Size: SH
  1. Position the accelerator pedal assembly to the brake pedal bracket.

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

  2. Install the accelerator pedal and sensor assembly mounting bolts.

    3. Tighten
    Tighten the bolts to 9 N·m (80 lb in).


    Object Number: 878813 Size: SH
  3. Install the brake pedal assembly, with the accelerator pedal assembly to the vehicle.
  4. Install the cruise control release switch, if equipped, to the pedal bracket. Refer to Cruise Control Release Switch Replacement .
  5. Install the stop lamp switch to the pedal bracket. Refer to Stop Lamp Switch Replacement .
  6. Move the brake pedal assembly to the installed position.

    7. Object Number: 878810 Size: SH
  7. Install the brake pedal bracket-to-steering column bracket bolt (1).

    8. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  8. Loosely install the brake booster mounting nuts.
  9. Apply a thin coating of high temperature grease, GM P/N 12345994 (Canadian P/N 10953501), to the pushrod pin on the brake pedal.
  10. Connect the brake booster pushrod (2) to the brake pedal.
  11. Install the washer (3) and retaining clip (4) to the brake pedal.
  12. Tighten the vacuum brake booster mounting nuts.

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

  13. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment .
  14. Adjust the cruise control release switch, if equipped. Refer to Cruise Release Switch Adjustment .

    15. Object Number: 927716 Size: SH
  15. Connect the electrical connector to the APP sensor.
  16. Secure the APP sensor jumper harness to the brake pedal bracket.
  17. Secure the EPS wiring harness to the pedal bracket.