GM Cavalier/Sunfire 1995-2000 Repair Guide

Brake Disc (Rotor)

Print

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6



Click image to see an enlarged view

Fig. Fig. 1: The brake caliper is mounted to the steering knuckle with two bolts



Click image to see an enlarged view

Fig. Fig. 2: Remove the brake caliper-to-steering knuckle retaining bolts



Click image to see an enlarged view

Fig. Fig. 3: Remove the brake caliper from the steering knuckle and ...



Click image to see an enlarged view

Fig. Fig. 4: ... support it using mechanic's wire or another suitable device



Click image to see an enlarged view

Fig. Fig. 5: Carefully slide the rotor from the hub and over the wheel lug nut studs ...



Click image to see an enlarged view

Fig. Fig. 6: ... and remove the rotor from the hub assembly

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the caliper mounting bolts.
  6.  
  7. Using mechanic's wire or another suitable device, support the caliper out of the way. Do not disconnect the brake hose from the caliper or allow the caliper to hang from the brake hose.
  8.  
  9. Slide the rotor off the hub.
  10.  

The rotor may have a rust build-up on it and will not slide off. If this happens a soft-faced or brass hammer should be used to aid in the removal of the rotor.

To install:
  1. Inspect the rotor for grooves, heat cracks or excessive run-out. A damaged rotor should be replaced.
  2.  
  3. If a new rotor is being installed the caliper piston will have to be pushed back into the caliper bore enough so the caliper will fit over the rotor. A large C-clamp or pair of pliers may be used to push the piston back into the caliper bore.
  4.  
  5. Slide the rotor onto the hub.
  6.  
  7. Install the caliper and caliper mounting bolts. Tighten the bolts to 40 ft. lbs. (54 Nm).
  8.  
  9. Install the tire and wheel assembly.
  10.  
  11. Lower the vehicle. Tighten the wheel lug nuts to 100 ft. lbs. (140 Nm).
  12.  
  13. Pump the brake pedal several times to seat the pads against the rotor before moving the vehicle.
  14.  
  15. Check and add brake fluid as necessary.
  16.  

INSPECTION



Check the disc brake rotor for scoring, cracks or other damage. Rotor run-out should be measured while the rotor is installed, while rotor thickness/thickness variation may be checked with the rotor installed or removed. Use a dial gauge to check rotor run-out. Check the rotor thickness to make sure it is greater than minimum thickness and check for thickness variations using a caliper micrometer.

Thickness Variation

See Figure 7



Click image to see an enlarged view

Fig. Fig. 7: Check brake rotor thickness in several places around the rotor

  1. Measure the thickness at four or more points on the rotor. Make all measure measurements at the same distance in from the edge of the rotor. Use a micrometer calibrated in ten-thousandths of an inch.
  2.  
  3. A rotor that varies in thickness by more than 0.0005 in. (0.013mm) can cause pedal pulsation and/or front end vibration during brake applications. A rotor that does not meet these specifications should be resurfaced to specifications or replaced.
  4.  

Lateral Run-out

See Figure 8



Click image to see an enlarged view

Fig. Fig. 8: Use the lug nuts to secure the rotor to the hub when checking rotor run-out

  1. Remove the wheel and tire assembly.
  2.  
  3. Fasten the lug nuts to retain the rotor.
  4.  
  5. Secure a dial indicator to the steering knuckle so the indicator button contacts the rotor at about 0.5 in. (13mm) from the outer edge of the rotor.
  6.  
  7. Set the dial indicator to zero.
  8.  
  9. Turn the wheel one complete revolution and observe the total indicated run-out.
  10.  
  11. If the run-out exceeds 0.003 in. (0.08mm), resurface or replace the rotor.
  12.  

 
label.common.footer.alt.autozoneLogo