Chevrolet Chevette/1000 1976-1988 Repair Guide

Brake Distribution and Warning Switch Assembly

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BRAKE WARNING LIGHT CHECK



  1. Disconnect the electrical lead from the switch terminal and use a jumper wire to connect the lead to a good ground.
  2.  
  3. Turn the ignition to the On position. The instrument panel warning lamp should light. If it does not light, either the bulb is burned out or the circuit is defective. Replace the bulb or repair the circuit as necessary.
  4.  
  5. When the warning lamp lights, turn the ignition off, remove the jumper wire, and connect the electrical lead to the brake line switch.
  6.  

TESTING



  1. Raise the car on a hoist and attach a bleeder hose to a rear bleed screw. Immerse the other end of the hose in a container partially filled with clean brake fluid. Check the master cylinder reservoir to make sure that it is full.
  2.  
  3. Turn the ignition switch to On. Open the bleed screw while an assistant applies heavy pressure to the brake pedal.
  4.  
  5. Repeat Step 2 on the front brake bleed screw. The warning lamp should light again. Turn the ignition OFF.
  6.  
  7. Lower the car. Check and fill the master cylinder reservoir to the correct level.
  8.  

If the warning lamp does not light during Steps 2 and 3, but does light when a jumper wire is connected to ground, the warning light switch is defective and must be replaced.

REMOVAL & INSTALLATION





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Fig. Fig. 1Brake distribution switch assembly mounting

The distribution and warning switch assembly is nonadjustable and non-serviceable. It must be replaced if defective.

  1. Disconnect the negative battery cable.
  2.  
  3. Clean the switch assembly thoroughly to remove dirt and foreign matter.
  4.  
  5. Disconnect the electrical lead from the switch.
  6.  
  7. Place dry rags below the switch to absorb any brake fluid which may be spilled.
  8.  
  9. Disconnect the hydraulic lines from the switch. If necessary, loosen the lines at the master cylinder to assist removal at the switch. Cover the open lines with a clean, lint-free material to prevent the entry of dirt.
  10.  
  11. Remove the mounting screw and remove the switch.
  12.  
  13. Make sure that the new switch is clean and free of dust and lint. If there is any doubt, wash the switch in clean brake fluid and dry with compressed air.
  14.  

To install:

  1. Place the switch in its installed position and install its mounting screws. Tighten the mounting screw to 100 in. lbs.
  2.  
  3. Remove the protective covering from the brake lines and connect the lines to the switch. If necessary, tighten the brake lines at the master cylinder. Tighten the brake line nuts at the switch and master cylinder to 150 in. lbs.
  4.  
  5. Connect the electrical lead to the switch.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Bleed the entire hydraulic system. Fill the master cylinder to within 1 / 4 " from the top of the reservoir after bleeding. Check for proper brake operation and leaks before moving the car.
  10.  

 
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