Cavalier, Sunfire 2001-2005

Brake Disc (Rotor)

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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.

  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
    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.


    NOTE
    Do NOT disconnect the hydraulic brake flexible hose from the caliper.

  4.  
  5. Remove the brake caliper with brake pads as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose.
  6.  
  7. Matchmark the position of the brake rotor to the wheel studs.
  8.  
  9. Remove the brake rotor.
    NOTE
    When a brake rotor has been separated from a hub/axle flange, the mating surface of the brake rotor must be cleaned of any rust or contaminants. Failure to do this may result in lateral runout of the brake rotor, and brake pulsation.

  10.  
  11. If the brake rotor is to be reinstalled to the vehicle, use the special tool J41013 in order to clean any rust or corrosion from the hub/axle flange mating surface of the brake rotor.
  12.  
  13. Use the special tool J42450-A in order to clean the wheel hub flange.
  14.  

To install:

Click image to see an enlarged view

Fig. Install the brake rotor (3) to the hub axle flange and the caliper assembly (2) to the steering knuckle.

  1. Install the brake rotor to the hub axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
  2.  
  3. Install the caliper assembly to the steering knuckle.
  4.  
  5. Install the tire and wheel assembly.
  6.  
  7. Lower the vehicle.
  8.  
  9. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors.
  10.  

 
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