GM Cavalier/Sunfire 1995-2000 Repair Guide

Wheel Cylinders

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7



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Fig. Fig. 1: Use a suitable size flarenut or line wrench ...



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Fig. Fig. 2: ... to loosen the brake line fitting from the wheel cylinder



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Fig. Fig. 3: Detach the connector for the rear wheel speed sensor



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Fig. Fig. 4: The hub retaining bolts are accessible through a hole in the hub flange



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Fig. Fig. 5: The hub retaining bolt nuts are accessible from behind the wheel



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Fig. Fig. 6: Insert a suitable tool through the hole in the hub flange and hold the retaining nut tight on the back of the hub, loosen the retaining bolts



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Fig. Fig. 7: Remove the hub and bearing assembly from the vehicle

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the rear tire and wheel assembly.
  4.  
  5. Thoroughly clean the area around the brake line connection and the retainer bolts. A generous application of penetrating oil may make brake line removal easier.
  6.  
  7. Disconnect the brake line from the back of the wheel cylinder and plug the opening in the line to prevent fluid loss and contamination.
  8.  
  9. Remove the brake drum.
  10.  
  11. Remove the hub and bearing assembly.
  12.  
  13. Remove the 2 bolts from the back of the wheel cylinder using a No. 6 TORX® socket.
  14.  
  15. Remove the wheel cylinder.
  16.  

To install:
  1. Install wheel cylinder and tighten bolts to 15 ft. lbs. (20 Nm).
  2.  
  3. Install hub and bearing assembly and tighten nut to 43 ft. lbs. (58 Nm).
  4.  
  5. Connect the brake line to wheel cylinder and tighten to 17 ft. lbs. (23 Nm).
  6.  
  7. Install the brake drum.
  8.  
  9. Bleed the brakes.
  10.  
  11. Install the wheel and tire assembly.
  12.  
  13. Lower the vehicle.
  14.  
  15. Check brake fluid level and fill as necessary.
  16.  
  17. Road test the vehicle and verify proper operation.
  18.  

OVERHAUL



See Figures 8 through 17

Wheel cylinder overhaul kits may be available, but often at little or no savings over a reconditioned wheel cylinder. It often makes sense with these components to substitute a new or reconditioned part instead of attempting an overhaul.

If no replacement is available, or you would prefer to overhaul your wheel cylinders, the following procedure may be used. When rebuilding and installing wheel cylinders, avoid getting any contaminants into the system. Always use clean, new, high quality brake fluid. If dirty or improper fluid has been used, it will be necessary to drain the entire system, flush the system with proper brake fluid, replace all rubber components, then refill and bleed the system.

  1. Remove the wheel cylinder from the vehicle and place on a clean workbench.
  2.  
  3. First remove and discard the old rubber boots, then withdraw the pistons. Piston cylinders are equipped with seals and a spring assembly, all located behind the pistons in the cylinder bore.
  4.  



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Fig. Fig. 8: Remove the outer boots from the wheel cylinder

  1. Remove the remaining inner components, seals and spring assembly. Compressed air may be useful in removing these components. If no compressed air is available, be VERY careful not to score the wheel cylinder bore when removing parts from it. Discard all components for which replacements were supplied in the rebuild kit.
  2.  



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Fig. Fig. 9: Compressed air can be used to remove the pistons and seals



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Fig. Fig. 10: Remove the pistons, cup seals and spring from the cylinder

  1. Wash the cylinder and metal parts in denatured alcohol or clean brake fluid.
  2.  



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Fig. Fig. 11: Use brake fluid and a soft brush to clean the pistons ...



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Fig. Fig. 12: ... and the bore of the wheel cylinder


WARNING
Never use a mineral-based solvent such as gasoline, kerosene or paint thinner for cleaning purposes. These solvents will swell rubber components and quickly deteriorate them.

  1. Allow the parts to air dry or use compressed air. Do not use rags for cleaning, since lint will remain in the cylinder bore.
  2.  
  3. Inspect the piston and replace it if it shows scratches.
  4.  



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Fig. Fig. 13: Once cleaned and inspected, the wheel cylinder is ready for assembly

  1. Lubricate the cylinder bore and seals using clean brake fluid.
  2.  
  3. Position the spring assembly.
  4.  
  5. Install the inner seals, then the pistons.
  6.  



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Fig. Fig. 14: Lubricate the cup seals with brake fluid



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Fig. Fig. 15: Install the spring, then the cup seals in the bore



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Fig. Fig. 16: Lightly lubricate the pistons, then install them

  1. Insert the new boots into the counterbores by hand. Do not lubricate the boots.
  2.  



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Fig. Fig. 17: The boots can now be installed over the wheel cylinder ends

  1. Install the wheel cylinder.
  2.  

 
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