Adjustable Pedal System: Removal & Installation Chevrolet Silverado 2500 HD

Removal Procedure

1. Remove the 2 master cylinder nuts.
2. Position the master cylinder aside and support with heavy mechanics wire or equivalent.
3. Remove the steering column from the vehicle. Refer to «Steering Column Replacement»(ref-278000-S15271124922008012100000) .
4. Remove the transmission range selector cable support bolt from the instrument panel (I/P) reinforcement brace.
5. Disconnect the electrical connectors from the following components: The adjustable pedals motor assembly The memory sensor connector, if equipped The pedal position sensor
6. Remove the accelerator pedal position sensor assembly. Refer to «Accelerator Pedal Position Sensor Replacement»(ref-278009-S14768855712008012100000) .
7. Remove the left side floor air outlet duct. Refer to «Floor Air Outlet Duct Replacement - Left Side»(ref-277995-S12586355462008012100000) .
8. Remove the brake booster pushrod retainer bolt (1).
9. Remove the brake booster pushrod retainer (1).
10. Remove the stoplamp switch (1).
11. Disconnect the brake booster pushrod from the brake pedal pivot.
12. Remove the adjustable pedal bracket nuts (1).
13. Remove the adjustable pedal bracket bolt (1).
14. Position the brake booster forward until the studs are past the adjustable pedal bracket holes.
15. Remove the adjustable pedal assembly from the vehicle.

Installation Procedure

1. With the aid of an assistant, position the brake booster to the vehicle.
2. Install the adjustable pedal assembly to the vehicle.
3. Hand install the adjustable pedal bracket bolt (1).
4. Install the adjustable pedal bracket nuts (1). Tighten: Tighten the nuts to 25 N.m (18 lb ft).
5. Tighten the adjustable pedal bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
6. Connect the brake booster pushrod from the brake pedal pivot.
7. Install the stoplamp switch (1).
8. Install the brake booster pushrod retainer (1).
9. Install the brake booster pushrod retainer bolt (1). Tighten: Tighten the bolt to 10 N.m (89 lb in).
10. Install the accelerator pedal position sensor assembly. Refer to «Accelerator Pedal Position Sensor Replacement»(ref-278009-S14768855712008012100000) .
11. Connect the electrical connectors to the following components: The adjustable pedals motor assembly The memory sensor connector, if equipped The pedal position sensor
12. Install the transmission range selector cable support bolt to the I/P reinforcement brace. Tighten: Tighten the bolt to 10 N.m (89 lb in).
13. Install the steering column to the vehicle. Refer to «Steering Column Replacement»(ref-278000-S15271124922008012100000) .
14. Install the left side floor air outlet duct. Refer to «Floor Air Outlet Duct Replacement - Left Side»(ref-277995-S12586355462008012100000) .
15. Install the master cylinder to the brake booster.
16. Install the 2 master cylinder nuts. Tighten: Tighten the nuts to 33 N.m (24 lb ft).
17. Verify the correct operation of the adjustable pedals.

1. Remove the driver knee bolster. Refer to «Knee Bolster Replacement (without RPO SLT)»(ref-277985-S03195852892008012100000) or «Knee Bolster Replacement (with RPO SLT)»(ref-277985-S32221400142008012100000) .
2. Remove the accelerator pedal position sensor assembly. Refer to «Accelerator Pedal Position Sensor Replacement»(ref-278009-S14768855712008012100000) .
3. Remove the accelerator pedal bracket nuts.
4. Remove the adjustable pedal drive cable from the accelerator pedal actuator using the following procedure: Twist the cable housing counterclockwise. Compress the secondary locking tabs located below the twist and lock tabs with a pointed tool and remove the cable from the pedal actuator.
5. Remove the accelerator pedal bracket nuts from the accelerator pedal bracket.
6. Remove the accelerator actuator lower pivot pin push nut (1) and washer (2).
7. Remove the accelerator actuator lower pivot pin (3).
8. Remove the accelerator actuator mounting screws (1).
9. Remove the accelerator actuator (2).

1. Install the accelerator actuator (2) to the accelerator pedal bracket.
2. Install the accelerator actuator screws (1). Tighten: Tighten the screws to 2.5 N.m (22 lb in).
3. Install the accelerator actuator lower pivot pin (3).
4. Install the accelerator actuator lower pivot pin washer (2) and push nut (1). In order to allow proper actuation of the adjustable bracket, the push nut must allow some free play of the pivot pin. The distance between the bracket side wall and the push nut should be 1.7 mm (0.07 in).
5. Install the drive cable (1) into the accelerator actuator (2) until secured by the secondary locking tabs.
6. Install and twist the cable housing to secure to the accelerator pedal assembly.
7. Install the accelerator pedal bracket mounting nuts. Tighten: Tighten the nuts to 9 N.m (80 lb in).
8. Adjust the accelerator pedal mounting bracket using the following procedure: Remove the screws from the cable housing at the top of the adjustable pedal motor. Twist the cable housing to unlock the cable from the motor. Remove the cable from the adjustable pedal motor. Attach a drill motor or equivalent to the adjustable pedal cable. Spin the cable until there is a distance of 6.14 mm (0.24 in) between the arrows on the inboard side of the adjustable pedal bracket.
9. Install the accelerator pedal position sensor assembly. Refer to «Accelerator Pedal Position Sensor Replacement»(ref-278009-S14768855712008012100000) .
10. Install the driver knee bolster. Refer to «Knee Bolster Replacement (without RPO SLT)»(ref-277985-S03195852892008012100000) or «Knee Bolster Replacement (with RPO SLT)»(ref-277985-S32221400142008012100000) .
11. Verify operation of the adjustable pedals.