Bonneville, LeSabre, Park Avenue 2000-2005

Brake Caliper

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Removal & Installation




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.

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.

  1. Raise the vehicle and suitably support.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Pull down on the front park brake cable.
  6.  
  7. Remove the front park brake cable from the park brake cable connector.
    NOTE
    When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in.) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  8.  
  9. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. Compress the brake caliper piston into brake caliper bore to allow the piston enough clearance to slide the brake caliper off the brake rotor.
  10.  
  11. Remove the C-clamp.
    NOTE
    Be sure to plug the opening in the brake caliper and brake hose to prevent fluid loss and/or contamination.

  12.  
  13. Remove brake hose to caliper bolt attaching the brake hose to the brake caliper.
  14.  
  15. Remove the brake hose from the brake caliper.
  16.  
  17. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  18.  
  19. Remove the park brake cable bracket from the brake caliper. Leave the park brake cable attached to the cable bracket.
  20.  
  21. Disconnect the park brake cable from the park brake lever on the brake caliper.
  22.  
  23. Remove the lower brake caliper pin bolt.
  24.  
  25. Rotate the brake caliper up.
  26.  
  27. Remove the brake caliper from the upper brake caliper pin bolt.
  28.  

To install:

  1. If reusing the brake caliper retainers, clean the sleeves using denatured alcohol, or equivalent.
  2.  
  3. Lubricate the brake caliper pin bolts with a thin coat of high temperature silicone lube.
  4.  
  5. Install the brake caliper to the upper caliper pin bolt.
  6.  
  7. Rotate the brake caliper down over the brake pads into the brake caliper bracket.
  8.  
  9. Install the brake caliper pin bolts. Tighten the brake caliper pin bolts to 27 Nm (20 ft. lbs.).
  10.  
  11. Remove the plugs in the brake hose end.
    NOTE
    Install NEW copper brake hose gaskets.

  12.  
  13. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
  14.  
  15. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 44 Nm (33 ft. lbs.).
  16.  
  17. Connect the park brake cable to the park brake lever on the brake caliper.
  18.  
  19. Install the park brake cable bracket to the brake caliper. Tighten the park brake cable bracket bolt to 43 Nm (32 ft. lbs.).
  20.  
  21. Install the front park brake cable to the park brake cable connector.
  22.  
  23. Bleed the brake system.
  24.  
  25. With the engine OFF, gradually apply the brake pedal to approximately 2 / 3 of its travel distance.
  26.  
  27. Slowly release the brake pedal.
  28.  
  29. Wait 15 seconds, then repeat until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  30.  
  31. Install the tire and wheel assembly.
  32.  
  33. Lower the vehicle.
  34.  


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 park brake cable from the caliper.
  18.  
  19. Remove the caliper from the vehicle.
  20.  
  21. Remove the brake pads.
  22.  

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 park brake cable.
  8.  
  9. 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

  10.  
  11. 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.
  12.  
  13. Connect the brake hose to the caliper. Install the brake hose banjo bolt, using new gaskets, and torque to 33 ft. lbs. (45 Nm).
  14.  
  15. Remove the lug nuts used to secure the rotor.
  16.  
  17. Install the wheel, aligning the reference marks made during removal, and torque the lug nuts to 100 ft. lbs. (140 Nm).
  18.  
  19. Refill the master cylinder and bleed the brake system using the recommended procedure.
  20.  
  21. Road test the vehicle and check for proper braking performance
  22.  

 
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