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Brake Pedal Assembly: Installation

  1. Install the brake pedal assembly.
  2. Install the upper and the lower mounting nuts to the brake pedal assembly. See Figure. Tighten the mounting nuts to specification. See TORQUE SPECIFICATIONS .
  3. Connect the brake pedal pushrod to the brake pedal. See Figure. Connect the electrical harness to the brake pedal.
    NOTE: The brake pedal must be attached to the power booster rod and undisturbed during the switch install. DO NOT press the brake pedal during the installation of the switch.
  4. Install the stoplight switch to the brake pedal.
    1. Install the stoplight switch into the retainer. See Fig 1.
      NOTE: Approximately 2-3 lbs of force is required to depress the switch plunger flush with the switch barrel. Too much force could flex the brake pedal bracket and result in the stoplight switch not being properly adjusted.
    2. Push the stoplight switch into the retainer until the switch plunger is fully depressed into the switch barrel.
    3. Rotate the stoplight switch clockwise until the travel stop has been reached.
    4. With a feeler gage check to ensure the minimum plunger extension is not less than 0.0" (0.0 mm), and not greater than 0.78" (2.0 mm) between the stoplight switch barrel and the brake pedal bracket.
    5. Connect the electrical connectors to the stoplight switch.
    NOTE: DO NOT route flexible components (hoses, wires, conduits, etc.) within 2" (50 mm) of moving parts unless flexible components can be securely fastened. This is necessary in order to prevent possible interference and damage to the component.
  5. Connect the accelerator cable to the accelerator pedal.
    1. Install accelerator cable using the routing noted during removal.
    2. Install the snap retainer through the bulkhead. Connect the accelerator cable in the slot in the accelerator pedal lever. See Figure. Seat the snap retainer in the accelerator pedal lever.
    3. Connect the accelerator cable to the throttle body lever, to the accelerator cable bracket and into the retaining clip.
    4. Reinstall the accelerator cable shield, if equipped.
    5. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect for poor carpet fit under the accelerator pedal.
    6. Inspect the throttle should operate freely, without binding, between full closed and wide open throttle.
  6. Install the left instrument panel insulator. Install the right half of the sound insulator on the drivers side to the instrument panel (I/P) carrier and install the bolts to the sound insulator. See Figure. Tighten the bolts to specification. See TORQUE SPECIFICATIONS . Install the left half of the sound insulator on the drivers side to the I/P carrier and install the push pin.
Fig 1: Installing Stoplight Switch
G00311316Courtesy of GENERAL MOTORS CORP.
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