Cavalier, Sunfire 2001-2005

Brake Pads

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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. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Siphon 2 / 3 of the brake fluid out of the master cylinder reservoir.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special caliper piston retracting tool.
  8.  
  9. Remove the caliper mounting bolts and sleeves.
  10.  
  11. Remove the caliper from the steering knuckle without disconnecting the brake hose. Do not allow the caliper to hang from the brake hose. Support the caliper with a piece of wire.
  12.  
  13. Remove the outboard pad by pushing in on the outside edge of the pad to release the mounting dowel from the hole in the caliper. When both dowels are unseated, push the pad out the bottom of the caliper.
  14.  
  15. Remove the inboard pad from the caliper by pulling it out of the caliper.
  16.  

To install:

  1. Inspect the caliper for any signs of leakage. If the caliper is leaking, new brake pads will be damaged. Also inspect the condition of the caliper support for rust and corrosion which will hinder the travel on the caliper.
  2.  
  3. Inspect the caliper mounting hardware. New bolts are usually recommended. Clean all parts well. Lubricate the mounting bushings and sleeves with silicone grease as required.
  4.  
  5. Install the inboard pad in the caliper so the spring clip on the pad back engages in the caliper piston.
  6.  
  7. Install the outboard pad over the caliper end until the mounting dowels snap into the mounting holes in the caliper.
  8.  
  9. Install the caliper over the rotor onto the steering knuckle.
  10.  
  11. Install the mounting bolts and sleeves and torque to 38 ft. lbs. (51 Nm).
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Pump the brake pedal several times to seat the pads against the rotor before attempting to move the vehicle.
  16.  
  17. Check the master cylinder level and add fluid as necessary.
  18.  

  1. Siphon 2 / 3 of the brake fluid out of the master cylinder reservoir.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special caliper piston retracting tool.
  6.  
  7. Remove the caliper mounting bolts and sleeves.
  8.  
  9. Remove the caliper from the steering knuckle without disconnecting the brake hose. Do not allow the caliper to hang from the brake hose. Support the caliper with a piece of wire.
  10.  
  11. Remove the outboard pad by pushing in on the outside edge of the pad to release the mounting dowel from the hole in the caliper. When both dowels are unseated, push the pad out the bottom of the caliper.
  12.  
  13. Remove the inboard pad from the caliper by pulling it out of the caliper.
  14.  

To install:

  1. Inspect the caliper for any signs of leakage. If the caliper is leaking, new brake pads will be damaged. Also inspect the condition of the caliper support for rust and corrosion which will hinder the travel on the caliper.
  2.  
  3. Inspect the caliper mounting hardware. New bolts are usually recommended. Clean all parts well. Lubricate the mounting bushings and sleeves with silicone grease as required.
  4.  
  5. Install the inboard pad in the caliper so the spring clip on the pad back engages in the caliper piston.
  6.  
  7. Install the outboard pad over the caliper end until the mounting dowels snap into the mounting holes in the caliper.
  8.  
  9. Install the caliper over the rotor onto the steering knuckle.
  10.  
  11. Install the mounting bolts and sleeves and torque to 40 ft. lbs. (51 Nm).
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Pump the brake pedal several times to seat the pads against the rotor before attempting to move the vehicle.
  16.  
  17. Check the master cylinder level and add fluid as necessary.
  18.  

 
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