GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Astro - 4WD 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Brake Pedal Assembly Replacement

Removal Procedure

    Object Number: 161625 Size: SH
  1. Remove the booster pushrod (4) and stoplamp switch (2) from brake pedal (1). Refer to Stop Lamp Switch Replacement .
  2. Remove the nut from the brake pedal pivot bolt.
  3. Remove the brake pedal pivot bolt.
  4. Remove the brake pedal (1), spacers and bushings from the vehicle.

Installation Procedure

    Object Number: 161625 Size: SH
  1. Install the brake pedal (1) to the vehicle.
  2. Install the through bolt, spacers and bushings to the vehicle.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the nut to the brake pedal pivot bolt.

    4. Tighten
    Tighten the nut to 45 N·m (33 lb ft).

  4. Install the booster pushrod (4) and the stoplamp switch (2) to the brake pedal (1). Refer to Stop Lamp Switch Replacement .