Bonneville, LeSabre, Park Avenue 2000-2005

Brake Caliper

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Removal & Installation




NOTE
The Bosch 2U ABS system cannot increase brake pressure above master cylinder pressure applied by during braking. There is no need to depressurize the system prior to service.

  1. Remove brake fluid from the master cylinder reservoir until the reservoir is approximately 1 / 3 full.
  2.  
  3. Remove the front wheel. Mark the position of the wheel to the wheel studs, prior to removal, for installation reference.
  4.  
  5. Install 2 lug nuts to retain the rotor once the caliper is removed.
  6.  
  7. Using a large C-clamp, bottom the piston in the caliper bore by positioning the C-clamp on the outboard pad and on the round portion of the brake caliper where the piston is housed.
  8.  
  9. Remove the banjo bolt that fastens the brake hose to the brake caliper. Discard the gaskets.
  10.  
  11. Cap the brake line to avoid excessive fluid loss or fluid contamination.
  12.  
  13. Remove the rubber dust boots from the caliper mounting bolt heads (if equipped).
  14.  
  15. Remove the caliper mounting bolts.
  16.  
  17. Remove the caliper from the vehicle.
  18.  
  19. Remove the brake pads.
  20.  

To install:

  1. Install the brake pads. Lubricate the slides where the caliper mounts on the steering knuckle with silicone grease.
  2.  
  3. Install the caliper over the rotor.
  4.  
  5. Install the caliper mounting bolts. Torque the mounting bolts to 38 ft. lbs. (51 Nm).
  6.  
  7. Install the rubber dust boots over the caliper mounting bolt heads (if equipped).

    Click image to see an enlarged view

    Fig. Measuring the caliper clearance

  8.  
  9. Check the clearance between the brake caliper and caliper bracket stops. If the clearance is too tight, check the caliper leading and trailing edges for build up. File down as necessary.
  10.  
  11. Connect the brake hose to the caliper. Install the brake hose banjo bolt, using new gaskets, and torque to 33 ft. lbs. (45 Nm).
  12.  
  13. Remove the lug nuts used to secure the rotor.
  14.  
  15. Install the wheel, aligning the reference marks made during removal, and torque the lug nuts to 100 ft. lbs. (140 Nm).
  16.  
  17. Refill the master cylinder and bleed the brake system using the recommended procedure.
  18.  
  19. Road test the vehicle and check for proper braking performance
  20.  

Except V8

CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Inspect the fluid level in the brake master cylinder reservoir. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Install and hand tighten 2 wheel lug nuts to retain the rotor to the hub.
  8.  
  9. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  10.  
  11. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  12.  
  13. Remove the C-clamp from the caliper.
  14.  
  15. Remove the brake hose to caliper bolt from the brake caliper.
  16.  
  17. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  18.  
  19. Plug the opening in the brake caliper and hose to prevent fluid loss and contamination.
    NOTE
    The upper caliper pin bolt, has a bushing as part of the bolt. The lower caliper pin bolt, is of a solid design.

  20.  
  21. Remove the caliper pin bolts. Note the location of the caliper pin bolts.
  22.  
  23. Remove the caliper from the caliper bracket.
  24.  
  25. Inspect the caliper pin bolt boots in the caliper bracket.

    Click image to see an enlarged view

    Fig. Front caliper-exc. Bonneville V8

  26.  

To install:

  1. If reusing the brake caliper pin bolts, wipe the old grease from the brake caliper pin bolts with a clean shop towel.
    NOTE
    DO NOT apply lubricant to the brake pad hardware.

  2.  
  3. Apply a thin coat of NIGLUBE® grease to the brake caliper pin bolts. It is not necessary to apply lubricant to the brake pad hardware or the threads of the caliper pin bolts.
  4.  
  5. Install the brake caliper over the brake pads into the brake caliper bracket.
    NOTE
    The upper caliper pin bolt, has a bushing as part of the bolt. The lower caliper pin bolt, is of a solid design.

  6.  
  7. Install the caliper pin bolts. Tighten the brake caliper pin bolts to 85 Nm (63 ft. lbs.).
    NOTE
    Install NEW copper brake hose gaskets.

  8.  
  9. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
  10.  
  11. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 44 Nm (32 ft. lbs.).
  12.  
  13. Bleed the brake system.
  14.  
  15. With the engine OFF, gradually apply the brake pedal to approximately 2 / 3 of its travel distance.
  16.  
  17. Slowly release the brake pedal.
  18.  
  19. Wait 15 seconds, then repeat until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  20.  
  21. Remove the 2 wheel lug nuts retaining the brake rotor to the hub.
  22.  
  23. Install the tire and wheel assembly.
  24.  
  25. Lower the vehicle.
  26.  

V8

CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Inspect the fluid level in the brake master cylinder reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  4.  
  5. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Remove the tire and wheel assembly.
  10.  
  11. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  12.  
  13. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  14.  
  15. Remove the C-clamp from the caliper.
  16.  
  17. Remove the brake hose-to-caliper bolt attaching the brake hose to the brake caliper.
  18.  
  19. Remove the brake hose from the brake caliper.
  20.  
  21. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  22.  
  23. Plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
  24.  
  25. Remove the brake caliper pin bolts.
  26.  
  27. Remove the brake caliper from the brake caliper bracket.

    Click image to see an enlarged view

    Fig. Bonneville V8 front caliper removal

  28.  

To install:


NOTE
Ensure that the caliper guide pin boots are fully seated to the caliper guide pin retaining seat of the caliper guide pin. Ensure that the caliper guide pin boots are fully seated to the caliper boot seal retaining seat of the brake caliper mounting bracket.

  1. Inspect the caliper guide pin boots for cuts, tears, or deterioration. If damaged, replace the slides and boots.
    NOTE
    If reusing the brake caliper pin bolts, the threads of the caliper pin bolts and the threads of the caliper bracket mounting holes must be free of residue and debris prior to application of threadlocker in order to ensure proper adhesion and fastener retention.

  2.  
  3. Prepare the bolts and the threaded holes for assembly: Thoroughly clean the residue from the bolt threads by using denatured alcohol or equivalent and allow to dry. Thoroughly clean the residue from the threaded holes by using denatured alcohol or equivalent and allow to dry.
  4.  
  5. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to 2 / 3 of the threaded length of the lower caliper bracket bolts. Ensure that there are no gaps in the threadlocker along the length of the filled area of the bolts.
  6.  
  7. Allow the threadlocker to cure approximately 10 minutes before installation.
  8.  
  9. Apply a thin coat of high temperature silicone brake lubricant to the brake caliper pin bolts.
  10.  
  11. Install the brake caliper pin bolts. Tighten the brake caliper pin bolts to 34 Nm (25 ft. lbs.).
  12.  
  13. Remove the plug from the brake caliper opening and the brake hose.
    NOTE
    Install NEW copper brake hose gaskets.

  14.  
  15. Assemble the NEW copper brake hose gaskets, and the brake caliper bolt to the brake hose.
  16.  
  17. Install the brake hose and the brake caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 44 Nm (32 ft. lbs.).
  18.  
  19. Bleed the hydraulic brake system.
  20.  
  21. With the engine OFF, gradually apply the brake pedal to approximately 2 / 3 of its travel distance.
  22.  
  23. Slowly release the brake pedal.
  24.  
  25. Wait 15 seconds, then repeat steps 11 and 12 until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  26.  
  27. Install the tire and wheel assembly.
  28.  
  29. Lower the vehicle.
  30.  

 
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