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

Removal Procedure
  1. Remove the instrument panel (I/P) lower closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
  2. Remove the accelerator pedal assembly from the brake pedal bracket to improve access to the brake pedal pivot nut. Refer to Accelerator Pedal Position Sensor Replacement for the 2.0L engine or Accelerator Pedal with Position Sensor Assembly Replacement for the 2.4L engine.
  3. Remove the clutch pedal assembly, if equipped, for removal of the brake pedal pivot bolt. Refer to Clutch Pedal Replacement.

    4. Object Number: 2179388 Size: SH
  4. Remove the power brake booster pushrod nut (1).
  5. Disconnect the power brake booster pushrod from the power brake booster pushrod pin.

    6. Object Number: 2179389 Size: SH
  6. While holding the brake pedal pivot bolt (1) stationary, remove the brake pedal pivot nut (2).
  7. Remove the brake pedal assembly and pivot bushings.

Installation Procedure
  1. Apply a thin coat of high-temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the brake pedal pivot bushing, the pushrod washer, the push rod pin on the pedal, and the brake pedal pivot pin.

    2. Object Number: 2179389 Size: SH
  2. Install the brake pedal assembly and pivot bushings.

    3. Ensure the brake pedal position switch actuator pin is engaged in the fork of the brake pedal position sensor.

  3. Install the brake pedal pivot bolt (1).
  4. Loosely install the brake pedal pivot nut (2).

    5. Caution: Refer to Fastener Caution in the Preface section.

  5. While holding the brake pedal pivot bolt stationary, tighten the brake pedal pivot nut to  50 N·m (37 lb ft).

    6. Object Number: 2179388 Size: SH
  6. Connect the power brake booster pushrod to the power brake booster pushrod pin.
  7. Install the power brake booster pushrod nut (1) and tighten to  10 N·m (89 lb in).
  8. Install the clutch pedal assembly, if equipped. Refer to Clutch Pedal Replacement.
  9. Install the accelerator pedal assembly to the brake pedal bracket. Refer to Accelerator Pedal Position Sensor Replacement for the 2.0L engine or Accelerator Pedal with Position Sensor Assembly Replacement for the 2.4L engine.
  10. Install the instrument panel (I/P) lower closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side.
  11. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.