Chevrolet Nova/ChevyII 1962-1979

Brake Caliper

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REMOVAL & INSTALLATION



1967-68 Chevy II


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Fig. Fig. 1 Exploded view of the disc brake caliper assembly-1967-68 vehicles

  1. Raise the front of the car and place it on jackstands.
  2.  
  3. Remove the tire and wheel assembly on the side where the caliper is being removed.
  4.  
  5. Disconnect the brake hose at the support bracket. Tape the end of the line to prevent contamination.
  6.  
  7. Remove the cotter pin from the brake pad retaining pin and remove the pin.
  8.  
  9. Remove the brake pads and identify them as inboard and outboard if they are being reused.
  10.  
  11. Remove the U-shaped retainer from the hose fitting and pull the hose from the bracket.
  12.  
  13. Remove the two caliper retaining bolts and remove the caliper from its mounting bracket.
  14.  

To install:

  1. While holding the brake pistons in with a putty knife, mount the caliper over the disc. Be careful not to damage the piston boots on the edge of the disc.
  2.  
  3. Install the two mounting bolts and tighten to 130 ft lbs.
  4.  
  5. Install the brake pads. (See brake pad installation.)
  6.  
  7. Install the brake hose into the caliper, passing the female end through the support bracket.
  8.  
  9. Make sure that the tube line is clean and connect the brake line nut to the caliper.
  10.  
  11. Install the hose fitting into the support bracket and install the U-shaped retainer. Turn the steering wheel from side to side to make sure that the hose doesn't interfere with the tire. If it does, turn the hose end one or two points in the bracket until the interference is eliminated.
  12.  
  13. After performing the above check, install the steel tube connector and tighten it.
  14.  
  15. Partially lower the vehicle, then bleed the brakes as outlined in this section.
  16.  
  17. Install the wheel(s) and lower the car.
  18.  

1969-79 Nova


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Fig. Fig. 2 Exploded view of the disc brake caliper assembly-1969-79 vehicles



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Fig. Fig. 3 Caliper lubrication points-1969-79 vehicles



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Fig. Fig. 4 If the caliper is being replaced or overhauled, unfasten the retainer ...



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Fig. Fig. 5 ... then disconnect the brake fluid line from the rear of the caliper

  1. Perform the removal steps for pad replacement.
  2.  
  3. Disconnect the brake hose and plug the line.
  4.  
  5. Remove the U-shaped retainer from the fitting.
  6.  
  7. Pull the hose from the frame bracket and remove the caliper with the hose attached.
  8.  
  9. Clean the outside of the caliper with denatured alcohol.
  10.  
  11. If the caliper is being removed for replacement or overhaul, remove the brake hose and discard the copper gasket.
  12.  
  13. Remove the brake fluid from the caliper.
  14.  
  15. Place clean rags inside the caliper opening to catch the piston when it is released.
  16.  
  17. Apply compressed air to the caliper fluid inlet hole and force the piston out of its bore. Do not blow the piston out, but use just enough pressure to ease it out.
  18.  
  19. Use a suitable prytool to pry the boot out of the caliper. Avoid scratching the bore.
  20.  
  21. Remove the piston seal from its groove in the caliper bore, using a plastic or wooden tool. Do not use a metal tool of any type for this operation.
  22.  
  23. Blow out all passages in the caliper and bleeder valve. Clean the piston and piston bore with fresh brake fluid.
  24.  
  25. Examine the piston for scoring, scratches, or corrosion. If any of these conditions exist, the piston must be replaced as it is plated and cannot be refinished.
  26.  
  27. Examine the bore for the same defects. Light rough spots may be removed by rotating crocus cloth, using finger-pressure, in the bore. Do not polish with an in-and-out motion or use any other abrasive.
  28.  
  29. Lubricate the piston bore and the new rubber parts with fresh brake fluid. Position the seal in the piston bore groove.
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  31. Lubricate the piston with brake fluid and assemble the boot into the piston groove so that the fold faces the open end of the piston.
  32.  
  33. Insert the piston into the bore, taking care not to unseat the seal.
  34.  
  35. Force the piston to the bottom of the bore. (This will require a force of 50-100 lbs.) Seat the boot lip around the caliper counterbore. Proper seating of the boot is very important for sealing out contaminants.
  36.  
  37. Install the brake hose into the caliper using a new copper gasket.
  38.  
  39. Lubricate the new sleeves and rubber bushings. Install the bushings in the caliper ears. Install the sleeves so that the end toward the disc pad is flush with the machined surface.
  40.  

Lubrication of the sleeves and bushings is essential to ensure the proper operation of the sliding caliper design.

  1. Install the shoe support spring in the piston.
  2.  
  3. Install the disc pads in the caliper and remount the caliper on the hub. (See Disc Pad Replacement.)
  4.  
  5. Reconnect the brake hose to the steel brake line. Install the retainer clip. Bleed the brakes (see Bleeding Brake System).
  6.  
  7. Replace the wheels, check the brake fluid level, check the brake pedal travel, and road-test the vehicle.
  8.  

 
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