Alero, Grand Am 1999-2005

Brake Disc (Rotor)

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Removal & Installation



  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.
  6.  
  7. Using the C-clamp, compress the piston into the caliper bore just enough to allow the caliper (1) to slide away from the rotor.
  8.  
  9. Remove the C-clamp.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  10.  
  11. Remove the caliper bracket bolts. Do not disconnect the brake flexible hose bolt.
  12.  
  13. Remove the brake caliper and the caliper mounting bracket as an assembly from the suspension knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose.
  14.  
  15. Matchmark the position of the brake rotor to the wheel studs.
  16.  
  17. Remove the brake rotor.
  18.  

To install:


NOTE
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Using a rotor resurfacing kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Using a hub resurfacing kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
  8.  
  9. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to the Brake Specifications Chart.
  10.  
  11. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to the Brake Specification Chart.
  12.  
  13. Install the brake caliper and the brake caliper bracket as an assembly to the suspension knuckle.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors, as follows:
    CAUTION
    Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage.


    NOTE
    Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced.

    1. Select a smooth road with little or no traffic.
    2.  
    3. Accelerate the vehicle to 48 km/h (30 mph).
      WARNING
      Use care to avoid overheating the brakes while performing this step.

    4.  
    5. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock.
    6.  
    7. Repeat until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors.
    8.  

  20.  

 
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