Corvette 1997-2005

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. Disconnect the negative battery cable and remove 2 / 3 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not allow the fluid to come into contact with the front transverse spring, as damage to the spring may occur.



    Wheel assembly
     
    Brake hose fitting at the caliper by removing the bolt. Discard the 2 copper washers and plug the hose to prevent fluid contamination or loss.
     



    Two caliper mounting bolts
     
    Caliper housing from the rotor and the caliper mounting bracket.
     

  4.  

To install:


NOTE
Inspect the caliper slide boots for damage and replace if necessary.

  1. Compress the pistons using a suitable tool, if necessary.
  2.  
  3. Install or connect the following:

    Caliper over the brake rotor and into the caliper mounting bracket. Make sure the shoe lining guiding surfaces are correctly seated in the bracket. Tighten the bolts to 23 ft. lbs. (31 Nm).
     
    Brake hose inlet fitting using two NEW copper washers and the inlet fitting bolt. Torque the bolt to 33 ft. lbs. (45 Nm).
     

  4.  
  5. Properly bleed the entire brake system.
  6.  
  7. Check the brake fluid and add as necessary.
  8.  
  9. Install the wheel.
  10.  
  11. Connect the negative battery cable, start the engine and pump the brake pedal slowly and firmly 3 times to seat the shoe and lining assemblies.

    Click image to see an enlarged view

    Fig. Exploded view of the front caliper assembly

  12.  

  1. Disconnect the negative battery cable and remove 2 / 3 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Mark the relationship between the wheel and axle flange, then remove the tire and wheel assembly.
  4.  
  5. Install 2 wheel nuts to retain the brake rotor.
  6.  
  7. Depress the caliper pistons into the caliper bores in order to provide clearance between the pads and the rotor.
  8.  
  9. Disconnect the brake hose fitting at the caliper by removing the bolt. Discard the 2 copper washers.
  10.  
  11. Plug all openings to prevent fluid contamination or loss.
    NOTE
    Do not allow the fluid to come into contact with the front transverse spring, as damage to the spring may occur.

  12.  
  13. For Corvette, remove the 2 caliper mounting bolts.
  14.  
  15. Remove the caliper housing from the rotor and the caliper mounting bracket.
  16.  

To install:

  1. Install the caliper over the brake rotor and into the caliper mounting bracket. Make sure the shoe lining guiding surfaces are correctly seated in the bracket.
  2.  
  3. Compress the bias springs by applying pressure to the mounting bracket, then install the new retainer pin.
  4.  
  5. Connect the brake hose inlet fitting using 2 new copper washers and the inlet fitting bolt. Torque the bolt to 30 ft. lbs. (40 Nm).
  6.  
  7. Properly bleed the entire brake system.
  8.  
  9. Remove the wheel nuts retaining the rotor, align the marks made earlier and install the tire and wheel assembly.
  10.  
  11. Check the brake fluid and add as necessary.
  12.  
  13. Connect the negative battery cable, start the engine and pump the brake pedal slowly and firmly 3 times to seat the shoe and lining assemblies.

    Click image to see an enlarged view

    Fig. Exploded view of the front caliper assembly-Corvette

  14.  

 
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