Chevrolet Sonic Repair Manual: Brake Pedal Assembly Replacement

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement.



2. Remove the power vacuum brake booster bolts (1).


3. Remove the brake pedal assembly upper nuts (1)


4. Remove the brake pedal assembly lower nuts (1)
5. Remove the steering column. Refer to Steering Column Replacement.



6. Remove the brake pedal release bracket bolt (1).


7. Remove the brake pedal release bracket bolts (1).


8. Remove the brake pedal release bracket (1).
9. Disconnect the brake pedal position sensor electrical connector.
10. On manual transmission equipped vehicles, disconnect the clutch pedal position sensor electrical connector.


11. On manual transmission equipped vehicles, disconnect the clutch master cylinder pushrod retainer (1). Refer to Clutch Master Cylinder Replacement



12. On manual transmission equipped vehicles, remove the clutch master cylinder bolts (1) and position aside the clutch master cylinder (2) without disconnecting the clutch fluid pipe. Clutch Master Cylinder Replacement
13. Position aside any wiring harnesses attached to the brake pedal assembly bracket, as necessary.


14. Remove the left upper brake pedal assembly bolt (1).


15. Remove the right upper brake pedal assembly bolt (1).


16. Using a suitable tool, carefully cut off the 2 upper brake pedal assembly locating pins (1).
17. Remove the brake pedal assembly from the vehicle.
18. Remove any necessary components from the brake pedal assembly.

Installation Procedure

1. Using a suitable tool, carefully cut off the 2 upper brake pedal assembly locating pins.
2. Install any removed components from the brake pedal assembly.
3. Install the brake pedal assembly to the vehicle.



Caution:

Refer to Fastener Caution.

4. Install the brake pedal assembly lower nuts (1) and tighten to  19 Y (14 lb ft)

   .





Caution:

Refer to Fastener Caution.

5. Install the brake pedal assembly upper nuts (1) and tighten to  19 Y (14 lb ft)

   .




6. Install the right upper brake pedal assembly bolt (1) and tighten to  9 Y (80 lb in)

   .




7. Install the left upper brake pedal assembly bolt (1) and tighten to  9 Y (80 lb in)

   .

8. Reposition any wiring harnesses attached to the brake pedal assembly bracket, as necessary.


9. On manual transmission equipped vehicles, install the clutch master cylinder bolts (1) and the clutch master cylinder (2). Refer to Clutch Master Cylinder Replacement.



10. On manual transmission equipped vehicles, connect the clutch master cylinder pushrod retainer (1). Refer to Clutch Master Cylinder Replacement.
11. On manual transmission equipped vehicles, connect the clutch pedal position sensor electrical connector.


12. Install the brake pedal release bracket (1).


13. Install the brake pedal release bracket bolts (1) and tighten to  22 Y (16 lb ft)

    .




14. Install the brake pedal release bracket bolt (1) and tighten to  22 Y (16 lb ft)

    .

15. Connect the brake pedal position sensor electrical connector.
16. Install the steering column. Refer to Steering Column Replacement.



17. Install the power vacuum brake booster bolts (1) and tighten to  19 Y (14 lb ft)

    .

18. Install the battery tray. Refer to Battery Tray Replacement.

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