Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo, Regal 2001-2005

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.

  1. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  2.  
  3. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes.
  4.  
  5. Install 2 wheel nuts to retain the rotor on the vehicle.
  6.  
  7. Install a large C-clamp over top of the caliper housing and against the back of the outboard shoe. Slowly tighten the C-clamp until the piston(s) are pushed into the caliper bore.
  8.  
  9. Disconnect the bolt attaching the brake hose fitting to the brake caliper.
  10.  
  11. Plug the opening in the caliper housing and brake line to prevent brake fluid loss and contamination.
  12.  
  13. Remove the caliper mounting bolts.
  14.  
  15. Remove the brake caliper housing from the rotor and mounting bracket.
  16.  
  17. If the caliper is to be replaced or repaired remove the brake pads from the caliper or mounting bracket.
  18.  

To install:

  1. Fully inspect the brake caliper bushing assemblies for cuts, tears or deterioration and replace parts as needed.
  2.  
  3. Inspect the slide bolts for corrosion. If corrosion is found, replace the slide bolts and bushings before installing the brake caliper assembly.
  4.  
  5. Before installing the caliper, make sure the piston(s) are seated in the bore, and that the brake pads are correctly installed.

    Click image to see an enlarged view

    Fig. Slide bolts lubrication points

  6.  
  7. Lubricate the caliper slide bolts with silicone grease. Do not lubricate the bolt threads.
  8.  
  9. Install brake pads onto caliper or mounting bracket.
  10.  
  11. Install the caliper bolts and torque the bolts to 70 ft. lbs. (95 Nm).
  12.  
  13. Install the brake hose inlet fitting to the caliper and torque the bolt to 24 ft. lbs. (32 Nm).
  14.  
  15. Remove wheel nuts securing the brake rotor to the hub.
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Fill the master cylinder to the proper level.
  20.  
  21. Bleed the brake system.
  22.  
  23. Verify correct brake operation.
  24.  

  1. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  2.  
  3. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes.
  4.  
  5. Install 2 wheel nuts to retain the rotor on the vehicle.
  6.  
  7. Install a large C-clamp over top of the caliper housing and against the back of the outboard shoe. Slowly tighten the C-clamp until the piston(s) are pushed into the caliper bore.
  8.  
  9. Disconnect the bolt attaching the brake hose fitting to the brake caliper.
  10.  
  11. Plug the opening in the caliper housing and brake line to prevent brake fluid loss and contamination.
  12.  
  13. Remove the caliper mounting bolts.
  14.  
  15. Remove the brake caliper housing from the rotor and mounting bracket.
  16.  
  17. If the caliper is to be replaced or repaired remove the brake pads from the caliper or mounting bracket.
  18.  

To install:

  1. Fully inspect the brake caliper bushing assemblies for cuts, tears or deterioration and replace parts as needed.
  2.  
  3. Inspect the slide bolts for corrosion. If corrosion is found, replace the slide bolts and bushings before installing the brake caliper assembly.
  4.  
  5. Before installing the caliper, make sure the piston(s) are seated in the bore, and that the brake pads are correctly installed.

    Click image to see an enlarged view

    Fig. Slide bolts lubrication points-Century, Regal, Lumina, Monte Carlo, Cutlass Supreme, Intrigue, Grand Prix

  6.  
  7. Lubricate the caliper slide bolts with silicone grease. Do not lubricate the bolt threads.
  8.  
  9. Install brake pads onto caliper or mounting bracket.
  10.  
  11. Install the caliper bolts and torque the bolts to 63 ft. lbs. (85 Nm).
  12.  
  13. Install the brake hose inlet fitting to the caliper and torque the bolt to 24 ft. lbs. (32 Nm).
  14.  
  15. Remove wheel nuts securing the brake rotor to the hub.
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Fill the master cylinder to the proper level.
  20.  
  21. Bleed the brake system.
  22.  
  23. Verify correct brake operation.
  24.  


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. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  2.  
  3. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes.
  4.  
  5. Install 2 wheel nuts to retain the rotor on the vehicle.
  6.  
  7. Install a large C-clamp over top of the caliper housing and against the back of the outboard shoe. Slowly tighten the C-clamp until the piston(s) are pushed into the caliper bore.
  8.  
  9. Disconnect the bolt attaching the brake hose fitting to the brake caliper.
  10.  
  11. Plug the opening in the caliper housing and brake line to prevent brake fluid loss and contamination.
  12.  
  13. Remove the caliper mounting bolts.
  14.  
  15. Remove the brake caliper housing from the rotor and mounting bracket.
  16.  
  17. If the caliper is to be replaced or repaired remove the brake pads from the caliper or mounting bracket.
  18.  

To install:

  1. Fully inspect the brake caliper bushing assemblies for cuts, tears or deterioration and replace parts as needed.
  2.  
  3. Inspect the slide bolts for corrosion. If corrosion is found, replace the slide bolts and bushings before installing the brake caliper assembly.
  4.  
  5. Before installing the caliper, make sure the piston(s) are seated in the bore, and that the brake pads are correctly installed.

    Click image to see an enlarged view

    Fig. Slide bolts lubrication points

  6.  
  7. Lubricate the caliper slide bolts with silicone grease. Do not lubricate the bolt threads.
  8.  
  9. Install brake pads onto caliper or mounting bracket.
  10.  
  11. Install the caliper bolts and torque the bolts to 70 ft. lbs. (95 Nm).
  12.  
  13. Install the brake hose inlet fitting to the caliper and torque the bolt to 24 ft. lbs. (32 Nm).
  14.  
  15. Remove wheel nuts securing the brake rotor to the hub.
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Fill the master cylinder to the proper level.
  20.  
  21. Bleed the brake system.
  22.  
  23. Verify correct brake operation.
  24.  

Rpo J65 & Jl9

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. Inspect the fluid level in the brake master cylinder reservoir.
  4.  
  5. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then 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, then remove brake fluid to the midway point before proceeding.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Remove the front tire and the wheel assembly.
  10.  
  11. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.
  12.  
  13. Install a large C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
  14.  
  15. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
  16.  
  17. Remove the C-clamp from the caliper.
  18.  
  19. Remove the brake hose-to-caliper bolt from the caliper. Discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  20.  
  21. Plug the opening in the front brake hose to prevent excessive brake fluid loss and contamination.
    NOTE
    Note the location of the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design.



    Click image to see an enlarged view

    Fig. Front caliper mounting-Except 2005 Grand Prix RPO Z7U

  22.  
  23. Remove the caliper pin bolts. Note the location of the caliper pin bolts. The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.
  24.  
  25. Remove the caliper from the rotor and the caliper bracket.
  26.  
  27. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots.
  28.  
  29. Inspect the caliper bolts for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts when installing the caliper.
  30.  

To install:

  1. If reusing the brake caliper pin bolts, wipe away any debris and old lubricant with a with a clean shop cloth.
  2.  
  3. Apply lubricant, GM P/N 18047666, or equivalent, to the brake caliper pin bolts. Apply a thin layer to the pin bushing and to the caliper pin bolt shank. Ensure that there is not a buildup of excess lubricant at the end of the leading caliper pin, in front of the bushing.
  4.  
  5. Install the caliper over the rotor and onto the caliper bracket.
    NOTE
    The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.

  6.  
  7. Install the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Ensure that the bolt boots fit securely in the groove of the caliper pin bolts. If the boots are damaged, they must be replaced. Tighten the bolts to 95 Nm (70 ft. lbs.).
    WARNING
    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 bolt to 54 Nm (40 ft. lbs.).
  12.  
  13. Remove the 2 wheel lug nuts retaining the rotor to the hub.
  14.  
  15. Install the front tire and the wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. Fill the master cylinder to the proper level with clean brake fluid.
  20.  
  21. Bleed the brake system.
  22.  
  23. Inspect the hydraulic brake system for brake fluid leaks.
  24.  

Rpo Z7u

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. Inspect the fluid level in the brake master cylinder reservoir.
  4.  
  5. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then 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, then remove brake fluid to the midway point before proceeding.
  6.  
  7. Raise and suitably support the vehicle.
  8.  
  9. Remove the front tire and the wheel assembly.
  10.  
  11. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.
  12.  
  13. Install a large C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
  14.  
  15. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
  16.  
  17. Remove the C-clamp from the caliper.
  18.  
  19. Remove the brake hose-to-caliper bolt from the caliper. Discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  20.  
  21. Plug the opening in the front brake hose to prevent excessive brake fluid loss and contamination.
  22.  
  23. Remove the caliper pin bolts.
  24.  
  25. Remove the caliper from the rotor and the caliper bracket.
  26.  
  27. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots.
  28.  
  29. Inspect the caliper bolts for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts when installing the caliper.
  30.  

To install:

  1. If reusing the brake caliper pin bolts, wipe away any debris and old lubricant with a with a clean shop cloth.
  2.  
  3. Apply lubricant, GM P/N 18047666, or equivalent, to the brake caliper pin bolts. Apply a thin layer to the pin bushing and to the caliper pin bolt shank. Ensure that there is not a buildup of excess lubricant at the end of the leading caliper pin, in front of the bushing.
  4.  
  5. Install the caliper over the rotor and onto the caliper bracket.
    NOTE
    The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.

  6.  
  7. Install the caliper pin bolts. Ensure that the bolt boots fit securely in the groove of the caliper pin bolts. If the boots are damaged, they must be replaced. Tighten the bolts to 44 Nm (60 ft. lbs.).
    WARNING
    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 bolt to 54 Nm (40 ft. lbs.).
  12.  
  13. Remove the 2 wheel lug nuts retaining the rotor to the hub.
  14.  
  15. Install the front tire and the wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. Fill the master cylinder to the proper level with clean brake fluid.
  20.  
  21. Bleed the brake system.
  22.  
  23. Inspect the hydraulic brake system for brake fluid leaks.
  24.  

 
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