GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 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. Remove the cruise control module, if equipped, from the brake pedal bracket. Refer to Cruise Control Module Replacement in Cruise Control.
  3. Remove the accelerator pedal mounting nuts. Reposition the accelerator pedal to improve tool access to the LH, lower booster mounting nut. Refer to Accelerator Pedal Replacement in Engine Controls - 2.2L.
  4. Loosen the brake booster mounting nuts.

    5. Object Number: 878810 Size: SH
  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 in Lighting Systems.
  11. Remove the cruise control release switch, if equipped, from the pedal bracket. Refer to Cruise Control Release Switch Replacement in Cruise Control.
  12. Remove the brake pedal assembly from the vehicle.

Installation Procedure

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

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


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

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

  6. Loosely install the brake booster mounting nuts.
  7. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal.
  8. Connect the brake booster pushrod (2) to the brake pedal.
  9. Install the washer (3) and retaining clip (4) to the brake pedal.
  10. Tighten the vacuum brake booster mounting nuts.

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

  11. Install the accelerator pedal into position and install the pedal mounting nuts. Refer to Accelerator Pedal Replacement in Engine Controls - 2.2L.
  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 Cruise Release Switch Adjustment in Cruise Control.
  14. Install the cruise control module, if equipped, to the brake pedal bracket. Refer to Cruise Control Module Replacement in Cruise Control.
  15. Secure the EPS wiring harness to the pedal bracket.