GM 25902025
Pedal Travel Sensor

When replacing the brake pedal assembly for automatic transaxle, instrument panel insulator should be removed first. Disconnect the brake pedal position sensor connector from its mounting, and remove nuts and washer at its end. Next, remove the vacuum brake booster nuts and the RH upper brake pedal bracket bolt and then removing the 2 LH upper brake pedal bracket bolts. Lift and take off the brake pedal assembly. To install, lift and locate the brake pedal assembly to the instrument panel tie bar, loosen the LH upper brake pedal bracket bolts (2), and the RH upper brake pedal bracket bolt and the vacuum brake booster nuts . Apply a thin layer of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) on the pushrod pin of the brake pedal, attach the brake pedal pushrod to the brake pedal pivot pin, and bolt the brake pedal pushrod washer. After that, tighten the vacuum brake booster nuts to 22 Nm (16 lb ft) and then the LH and RH upper brake pedal bracket bolts to 25 Nm (18 lb ft). Push on the brake pedal push rod nut and tighten it to 10 Nm (89 lb in) and reconnect the brake pedal position sensor electrical connector. Lastly, set up the brake pedal position sensor and add the instrument panel insulator back.

Place the Steering Column lower and set it to the side before moving on to Brake Pedal assembly replacement for automatic transaxles. Undo the connections of the Brake Pedal position sensor and break-free the power brake booster pushrod at the Brake Pedal assembly. First separate the Brake Pedal pushrod washer and vacuum brake booster nuts. Take off the rh upper Brake Pedal bracket bolt and the two bolts from the lh upper pedal bracket before removing the instrument panel tie bar. Lower the Brake Pedal unit off the vehicle. Set the Brake Pedal assembly on top of the power brake booster studs and insert the instrument panel tie bar. Set the two left-hand upper Brake Pedal bolts and the right-hand bolt along with the vacuum brake booster nuts loosely. Coat the Brake Pedal pushrod pin with high temperature grease gm p/n 12345996, attach the pushrod to the pedal pivot pin and put on the brake washer. Use 22 nm torque when securing the vacuum brake booster nuts and apply 25 nm torque to both upper Brake Pedal bracket bolts. Fasten the Brake Pedal pushrod turret with a torque of 10 nm while connecting the pedal position sensor electrical connections. Remove the Steering Column and install the Brake Pedal position sensor before putting back the steering assembly.

Loosely install the two LH upper brake pedal bracket bolts, the RH upper brake pedal bracket bolt, and the vacuum brake booster nuts.

Lower and remove the brake pedal and clutch pedal assembly.