GM Cavalier/Sunfire 1995-2000 Repair Guide

Brake Pads

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REMOVAL & INSTALLATION



See Figures 1 through 15



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Fig. Fig. 1: Remove the outer pad from the caliper by pressing the pad inward to release the mounting dowels from the center of the pad



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Fig. Fig. 2: Compress the piston using a C-clamp or other suitable tool



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Fig. Fig. 3: Remove the inboard pad by releasing the retaining clip from the piston



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Fig. Fig. 4: Clean the pad guide mounts on the steering knuckle. Make sure there is no rust or build-up present



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Fig. Fig. 5: Clean the caliper assembly of any build-up or rust before installing the new pads



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Fig. Fig. 6: Apply a coat of anti-squeal lubricant to the pads before installing the new pads



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Fig. Fig. 7: The inboard shoe and lining assembly has a retaining spring attached to the back



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Fig. Fig. 8: Install the inboard pad engaging the retaining spring on the back of the pad into the caliper piston



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Fig. Fig. 9: Insert the outboard pad and align the mounting dowels with the ...



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Fig. Fig. 10: ... centering holes in the center of the piston



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Fig. Fig. 11: Remove the mounting bolts and sleeve assembly from the caliper



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Fig. Fig. 12: Before installation, lubricate the caliper bushing cavity with silicone grease



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Fig. Fig. 13: Thoroughly clean the mounting bolt sleeves and ...



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Fig. Fig. 14: ... apply a suitable disc brake slide grease to the sleeves



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Fig. Fig. 15: With an assistant depressing the brake pedal, you must clinch the outboard shoe tabs so they are locked tightly in position


CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Remove 1 / 2 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Remove the caliper-to-steering knuckle mounting bolts.
  8.  
  9. Lift the caliper off of the steering knuckle and support it using mechanics wire or another suitable device to prevent damage to the brake hose.
  10.  

It may be necessary to compress the piston slightly to allow the removal of the caliper.

  1. Remove the outboard disc brake pad from the caliper.
  2.  
  3. Remove the inboard disc brake pad from the brake caliper.
  4.  

To install:
  1. Thoroughly clean the caliper and the steering knuckle where the pads contact.
  2.  
  3. If installing new disc brake pads, use a C-clamp or similar tool to push the caliper piston into the caliper bore. This will allow room for the new pads.
  4.  
  5. Coat the new pads with a suitable anti-squeal lubricant.
  6.  
  7. Place the outboard disc brake pad into position on the caliper ensuring that the mounting dowels are aligned with the holes in the caliper.
  8.  
  9. Place the inboard disc brake pad into the caliper piston and engaging the retaining clip.
  10.  
  11. Thoroughly clean the 2 mounting bolt sleeves and apply an appropriate coating of brake caliper slide grease, or another suitable lubricant.
  12.  
  13. Position the disc brake caliper onto the rotor.
  14.  
  15. Install the 2 mounting bolts and torque to 40 ft. lbs. (54 Nm).
  16.  
  17. Reinstall the wheel and tire assembly. Torque the lug nuts to 100 ft. lbs. (140 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle.
  22.  
  23. With an assistant depressing the brake pedal, you must clinch the outboard shoe tabs so they are locked tightly in position.
  24.  
  25. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary.
  26.  
  27. Road test the vehicle and check for proper brake system operation.
  28.  

INSPECTION



See Figure 16



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Fig. Fig. 16: Measuring the brake pad thickness to see if the pads need to be replaced

  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Looking down through the inspection hole on the top of the caliper, inspect the brake pads. If the lining is worn down to within 1 / 32 in. (0.8mm) of the shoe, the pads must be replaced.
  6.  

This figure may disagree with your state's automobile inspection laws.

If the brake lining is soaked with brake fluid or grease, it must be replaced. If this is the case, the brake rotor should be sanded with crocus cloth to remove all traces of brake fluid, and the calipers and lines should be inspected for leaks.

If the lining is chipped, cracked, or otherwise damaged, it must be replaced with a new lining.

Always replace the brake linings in sets of two on both ends of the axle. Never replace just one pad, or both on one side and not the other. When replacing the brakes, it is a good idea to replace one side at a time so that you always have an example to refer to if you get confused during reassembly.

 
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