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. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  4.  
  5. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes.
  6.  
  7. Install 2 wheel nuts to retain the rotor.
  8.  
  9. Remove the brake hose from the caliper and discard the copper washers.
  10.  
  11. Plug the openings in the caliper and the brake hose to prevent brake fluid loss and contamination.
  12.  
  13. Remove the two caliper mounting bolts.
  14.  
  15. Remove the caliper body assembly from the vehicle. Pivot the caliper assembly up to clear the rotor and then slide it inboard off the pin sleeve.

    Click image to see an enlarged view

    Fig. Caliper attachments-except 2005 Pontiac Grand Prix RPO Z7U

  16.  

To install:

  1. Inspect the caliper bolt boots, pins and sleeve bolt for cuts, tears or deterioration. Replace as necessary.
  2.  
  3. Lubricate the mounting surfaces and the mounting sleeves.
  4.  
  5. Hold the caliper body assembly in the position from which it was removed, and start it over the end of the pin sleeve.
  6.  
  7. As the caliper body assembly approaches the pin boot, work the large end of the pin boot in the caliper body groove. Push the caliper body fully onto the pin.
  8.  
  9. Pivot the caliper body assembly down, using care not to damage the piston boot on the inboard shoe. Compress the sleeve boot by hand as the caliper body moves into position to prevent boot damage.
  10.  
  11. After installing the caliper assembly into position, recheck the installation of the pad clips. If necessary, use a small prying tool to reset or center the pad clips.
  12.  
  13. Torque caliper mounting bolts to 32 ft. lbs. (43 Nm)
  14.  
  15. Connect the brake hose to the brake caliper and torque the bolt to 40 ft. lbs. (54 Nm).
  16.  
  17. Remove the wheel nuts securing the rotor to the hub and bearing assembly.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Fill the master cylinder to the proper level with clean brake fluid.
  22.  
  23. Bleed the brake system using the recommended procedure.
  24.  
  25. Apply approximately 175 lbs. (79 kg) of force, 3 times, to properly seat the brake shoe and linings against the rotor.
  26.  
  27. Adjust the parking brake cable as necessary (some models).
  28.  

  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.
  6.  
  7. Remove the brake hose from the caliper and discard the copper washers.
  8.  
  9. Plug the openings in the caliper and the brake hose to prevent brake fluid loss and contamination.
  10.  
  11. The following steps are for models with the park brake cable attached to the caliper:
    1. Disconnect the parking brake cable from the parking brake lever on the caliper. Lift up one end of the cable spring clip free end of the cable from the lever.
    2.  
    3. Remove the bolt and washer attaching the cable support bracket to the caliper body assembly.
    4.  
    5. Remove the caliper sleeve bolts.
    6.  

  12.  
  13. For all others, remove the two caliper mounting bolts.
  14.  
  15. Remove the caliper body assembly from the vehicle. Pivot the caliper assembly up to clear the rotor and then slide it inboard off the pin sleeve.
  16.  

To install:

  1. Inspect the caliper bolt boots, pins and sleeve bolt for cuts, tears or deterioration. Replace as necessary.
  2.  
  3. Lubricate the mounting surfaces and the mounting sleeves.
  4.  
  5. Hold the caliper body assembly in the position from which it was removed, and start it over the end of the pin sleeve.
  6.  
  7. As the caliper body assembly approaches the pin boot, work the large end of the pin boot in the caliper body groove. Push the caliper body fully onto the pin.
  8.  
  9. Pivot the caliper body assembly down, using care not to damage the piston boot on the inboard shoe. Compress the sleeve boot by hand as the caliper body moves into position to prevent boot damage.
  10.  
  11. After installing the caliper assembly into position, recheck the installation of the pad clips. If necessary, use a small prying tool to reset or center the pad clips.
  12.  
  13. Install the brake caliper sleeve bolts and torque to 20 ft. lbs. (27 Nm).
  14.  
  15. On models without caliper mounted park brake cable, torque caliper mounting bolts to 32 ft. lbs. (43 Nm)
  16.  
  17. To install the park brake cable, the following steps apply (some models).
    1. Install the cable support bracket with the cable attached. Torque bolt to 32 ft. lbs. (43 Nm).
    2.  
    3. Lift up on the end of the cable spring clip and work the end of the parking brake cable into the notch of the parking brake lever.
    4.  

  18.  
  19. Connect the brake hose to the brake caliper and torque the bolt to 32 ft. lbs. (44 Nm).
  20.  
  21. Remove the wheel nuts securing the rotor to the hub and bearing assembly.
  22.  
  23. Install the tire and wheel assembly.
  24.  
  25. Fill the master cylinder to the proper level with clean brake fluid.
  26.  
  27. Bleed the brake system using the recommended procedure.
  28.  
  29. Apply approximately 175 lbs. (79 kg) of force, 3 times, to properly seat the brake shoe and linings against the rotor.
  30.  
  31. Adjust the parking brake cable as necessary (some models).

    Click image to see an enlarged view

    Fig. Caliper attachments-Century, Regal, Lumina, Monte Carlo, Cutlass Supreme, Intrigue, Grand Prix

  32.  


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. Remove 2 / 3 of the brake fluid from the master cylinder assembly.
  4.  
  5. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes.
  6.  
  7. Install 2 wheel nuts to retain the rotor.
  8.  
  9. Remove the brake hose from the caliper and discard the copper washers.
  10.  
  11. Plug the openings in the caliper and the brake hose to prevent brake fluid loss and contamination.
  12.  
  13. Remove the two caliper mounting bolts.
  14.  
  15. Remove the caliper body assembly from the vehicle. Pivot the caliper assembly up to clear the rotor and then slide it inboard off the pin sleeve.

    Click image to see an enlarged view

    Fig. Caliper attachments-except 2005 Pontiac Grand Prix RPO Z7U

  16.  

To install:

  1. Inspect the caliper bolt boots, pins and sleeve bolt for cuts, tears or deterioration. Replace as necessary.
  2.  
  3. Lubricate the mounting surfaces and the mounting sleeves.
  4.  
  5. Hold the caliper body assembly in the position from which it was removed, and start it over the end of the pin sleeve.
  6.  
  7. As the caliper body assembly approaches the pin boot, work the large end of the pin boot in the caliper body groove. Push the caliper body fully onto the pin.
  8.  
  9. Pivot the caliper body assembly down, using care not to damage the piston boot on the inboard shoe. Compress the sleeve boot by hand as the caliper body moves into position to prevent boot damage.
  10.  
  11. After installing the caliper assembly into position, recheck the installation of the pad clips. If necessary, use a small prying tool to reset or center the pad clips.
  12.  
  13. Torque caliper mounting bolts to 32 ft. lbs. (43 Nm)
  14.  
  15. Connect the brake hose to the brake caliper and torque the bolt to 40 ft. lbs. (54 Nm).
  16.  
  17. Remove the wheel nuts securing the rotor to the hub and bearing assembly.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Fill the master cylinder to the proper level with clean brake fluid.
  22.  
  23. Bleed the brake system using the recommended procedure.
  24.  
  25. Apply approximately 175 lbs. (79 kg) of force, 3 times, to properly seat the brake shoe and linings against the rotor.
  26.  
  27. Adjust the parking brake cable as necessary (some models).
  28.  

Rpo J65 And 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, no brake fluid needs to be removed from the reservoir before proceeding.
  6.  
  7. 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.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the tire and wheel assembly.
  12.  
  13. Release tension from park brake system at the equalizer.
  14.  
  15. Disconnect the front and rear cables from one another at the connector clip.
  16.  
  17. Disconnect the park brake cable from the park brake lever on the brake caliper.
  18.  
  19. Remove the park brake cable from the caliper bracket.
  20.  
  21. Remove brake hose to caliper bolt.
  22.  
  23. Remove the brake hose from the brake caliper.
  24.  
  25. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  26.  
  27. Plug the opening in the brake caliper and brake hose to prevent fluid loss and/or contamination.
  28.  
  29. Remove the brake caliper bolts.
  30.  
  31. Remove the brake caliper.
  32.  

To install:

Click image to see an enlarged view

Fig. Align the indents on the piston face to match the pin on the brake pad

  1. Align the indents on the piston face to match the pin on the brake pad.
  2.  
  3. Inspect the bracket bolt guide assembly.
  4.  
  5. Inspect the brake pad hardware and replace if necessary.
  6.  
  7. Install the brake caliper onto the caliper bracket insuring that the guide boots are not damaged.
  8.  
  9. Install the brake caliper bolts. Tighten the brake caliper bolts to 34 Nm (25 ft. lbs.).
  10.  
  11. Remove the plugs in the brake hose end.
    WARNING
    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. When installing the right rear brake hose to caliper, hold hose up while tightening. Tighten the brake hose to caliper bolt to 44 Nm (33 ft. lbs.).
  16.  
  17. Install the park brake cable into the park brake bracket on the caliper.
  18.  
  19. Connect the park brake cable to the park brake lever on the brake caliper.
  20.  
  21. Bleed the brake system.
  22.  
  23. With the engine OFF, gradually apply the brake pedal to approximately  2 / 3 of its travel distance.
  24.  
  25. Slowly release the brake pedal.
  26.  
  27. Wait 15 seconds, then repeat steps 12-13 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  28.  
  29. Adjust the park brake system.
  30.  
  31. Install the tire and wheel assembly.
  32.  
  33. Lower the vehicle.
  34.  

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, no brake fluid needs to be removed from the reservoir before proceeding.
  6.  
  7. 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.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the tire and wheel assembly.
  12.  
  13. Release tension from park brake system at the equalizer.
  14.  
  15. Disconnect the front and rear cables from one another at the connector clip.
  16.  
  17. Disconnect the park brake cable from the park brake lever on the brake caliper.
  18.  
  19. Remove the park brake cable from the caliper bracket.
  20.  
  21. Remove brake hose to caliper bolt.
  22.  
  23. Remove the brake hose from the brake caliper.
  24.  
  25. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  26.  
  27. Plug the opening in the brake caliper and brake hose to prevent fluid loss and/or contamination.
  28.  
  29. Remove the brake caliper bolts.
  30.  
  31. Remove the brake caliper.
  32.  

To install:

  1. Inspect the bracket bolt guide assembly.
  2.  
  3. Inspect the brake pad hardware and replace if necessary.
  4.  
  5. Install the brake caliper onto the caliper bracket insuring that the guide boots are not damaged.
  6.  
  7. Install the brake caliper bolts. Tighten the brake caliper bolts to 44 ft. lbs. (60 Nm).
  8.  
  9. Remove the plugs in the brake hose end.
    WARNING
    Install NEW copper brake hose gaskets.

  10.  
  11. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
  12.  
  13. Install the brake hose to caliper bolt to the brake caliper. When installing the right rear brake hose to caliper, hold hose up while tightening. Tighten the brake hose to caliper bolt to 44 Nm (33 ft. lbs.).
  14.  
  15. Install the park brake cable into the park brake bracket on the caliper.
  16.  
  17. Connect the park brake cable to the park brake lever on the brake caliper.
  18.  
  19. Bleed the 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 12-13 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  26.  
  27. Adjust the park brake system.
  28.  
  29. Install the tire and wheel assembly.
  30.  
  31. Lower the vehicle.
  32.  

 
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