Crossfire, 2004-2005

Brake Caliper

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Removal & Installation



  1. Raise and support the front end on jackstands.
  2.  
  3. Drain a small amount of fluid from the master cylinder reservoir.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the brake pad wear indicator.
  8.  
  9. Press the caliper piston back into the bore with a suitable prytool. Use a large C-clamp to drive the piston into the bore of additional force is required.
  10.  
  11. Remove the caliper support spring.
  12.  
  13. Remove the caliper mounting pins.
  14.  
  15. Loosen the bolt that secures the front brake hose fitting bolt in the caliper.
  16.  
  17. Slide the caliper off the rotor and out from its mount.
  18.  
  19. Remove the front brake hose fitting bolt completely, then remove the caliper with the pads installed as an assembly. Take care not to drip fluid onto the pad surfaces.
  20.  
  21. Cover the open end of the front brake hose fitting to prevent dirt entry.

    Click image to see an enlarged view

    Fig. Brake pad wear indicator (2)



    Click image to see an enlarged view

    Fig. Caliper (1) and slide pins (2)

  22.  

To install:

  1. Lubricate the caliper slide pins and bushings with silicone grease.
  2.  
  3. Install the caliper over the rotor and seat it in its original position until flush.
  4.  
  5. Install the slide pins by hand, and then tighten them to 18 ft. lbs. (25 Nm).
  6.  
  7. Connect the brake hose.
  8.  
  9. Install the brake pad wear indicator. Tighten the bolt to 6 ft. lbs. (8 Nm).
  10.  
  11. Install the caliper support spring.
  12.  
  13. Install the wheels.
  14.  
  15. Lower the vehicle.
  16.  
  17. Pump the brakes several times to seat the pads.
  18.  

 
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