Chevrolet Citation/Omega/Phoenix/Skylark 1980-1985 Repair Guide

Caliper

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REMOVAL & INSTALLATION





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Fig. Fig. 1 When removing the caliper, use a flare nut wrench to loosen the union bolt



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Fig. Fig. 2 Be sure to replace the copper sealing washers



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Fig. Fig. 3 Remove the caliper allen head mounting bolts ...



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Fig. Fig. 4 ... then lift caliper up and off the rotor and steering knuckle

  1. Follow Steps 1, 2 and 3 of the pad replacement procedure.
  2.  
  3. Before removing the caliper mounting bolts, remove the bolt holding the brake hose to the caliper.
  4.  
  5. Remove the allen head caliper mounting bolts. Inspect them for corrosion and replace them if necessary.
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  7. Installation is the reverse. Mounting bolt torque is 21-35 ft. lbs. (28-47 Nm) for the caliper. The brake hose fitting should be tightened to 18-30 ft. lbs. (24-40 Nm).
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OVERHAUL





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Fig. Fig. 5 Use air pressure to remove the piston from the caliper bore



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Fig. Fig. 6 Carefully remove the piston boot using a small prytool



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Fig. Fig. 7 Use a plastic or wooden tool to remove the piston seal from the caliper



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Fig. Fig. 8 Exploded view of the disc brake caliper



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Fig. Fig. 9 Install the dust boot onto the piston as shown



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Fig. Fig. 10 Position the piston boot in the caliper housing and seat with a suitable seal driver

  1. Remove the caliper from the vehicle, as outlined earlier in this section.
  2.  
  3. Remove the pads.
  4.  
  5. Place some cloths or a slat of wood in front of the piston. Remove the piston by applying compressed air to the fluid inlet fitting. Use just enough air pressure to ease the piston from the bore.
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CAUTION
Do not try to catch the piston with your fingers, which can result in serious injury.

  1. Remove the piston boot with a prytool, working carefully so that the piston bore is not scratched.
  2.  
  3. Remove the bleeder screw.
  4.  
  5. Inspect the piston for scoring, nicks, corrosion, wear, etc., and damaged or worn chrome plating. Replace the piston if any defects are found.
  6.  
  7. Remove the piston seal from the caliper bore groove using a piece of pointed wood or plastic. Do not use a screwdriver, which will damage the bore. Inspect the caliper bore for nicks, corrosion, and so on. Very light wear can be cleaned up with crocus cloth. Use finger pressure to rub the crocus cloth around the circumference of the bore-do not slide it in and out. More extensive wear or corrosion warrants replacement of the part.
  8.  
  9. Clean any part which are to be reused in denatured alcohol. Dry them with compressed air or allow to air dry. Don't wipe the parts dry with a cloth, which will leave behind bits of lint.
  10.  
  11. Lubricate the new seal, provided in the repair kit, with clean brake fluid. Install the seal in its groove, making sure it is fully seated and not twisted.
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  13. Install the new dust boot on the piston. Lubricate the bore of the caliper with clean brake fluid and insert the piston into its bore. Position the boot in the caliper housing and seat with a seal driver of the appropriate size, or GM tool no. J-29077.
  14.  
  15. Install the bleeder screw, tightening to 80-140 inch lbs. (9-16 Nm). Do not overtighten.
  16.  
  17. Install the pads, install the caliper, and bleed the brakes.
  18.  

 
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