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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 129 (ADJUSTABLE PEDAL SYSTEM)REPAIR INSTRUCTIONSBRAKE PEDAL ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT: Ensure that the adjustable brake pedal and adjustable accelerator pedal are synchronized in the full rearward position.
  1. Insert a #4 square drive tool into the adjustable brake pedal actuator assembly and turn until the adjustable brake pedal assembly moves fully rearward.
    2. Fig 1: View Of Brake Pedal Assembly To Instrument Panel Carrier Bolts
    GM1242219Courtesy of GENERAL MOTORS CORP.
  2. Install the adjustable brake pedal assembly to the vehicle.
    3. NOTE: Refer to Fastener Notice .
  3. Install the 3 brake pedal assembly to I/P carrier bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    4. Fig 2: View Of Brake Pedal Assembly To Cowl Mounting Nuts
    GM1241592Courtesy of GENERAL MOTORS CORP.
  4. Install the 2 brake pedal assembly to cowl mounting nuts.

    Tighten:  Tighten the nuts to 15 N.m (11 lb ft).

    5. Fig 3: View Of Booster Pushrod Retaining Clip, Washers & Booster Pushrod
    GM1301945Courtesy of GENERAL MOTORS CORP.
  5. Install the booster pushrod retaining clip (1), the washers (2), and the booster pushrod (3) to the adjustable pedal pivot pin (4).
  6. Install the steering column assembly to the vehicle. Refer to Steering Column Replacement (Hydraulic Power Steering (HPS)) or Steering Column Replacement (Electronic Power Steering (EPS)) .
  7. Install the NEW cable. Refer to Brake Pedal Adjuster Actuator Cable Replacement .
  8. Install the electrical connector to the brake pedal adjustment position sensor.
  9. Install the electrical connector to the brake apply sensor.
  10. Install the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .
  11. Install the knee bolster. Refer to Knee Bolster Replacement .
  12. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.