GM Corsica/Beretta 1988-1996 Repair Guide

Caliper

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REMOVAL & INSTALLATION



  1. For 1988-91 vehicles, perform steps 1-3 of the brake pad replacement procedure.
  2.  
  3. For 1992-96 vehicles, perform steps 1-4 of the brake pad replacement procedure.
  4.  
  5. Unfasten the bolt securing the brake hose to the caliper. Plug or cap the brake line.
  6.  
  7. Remove the mounting bolts, then remove the caliper from the vehicle.
  8.  

  1. Inspect the caliper mounting bolts for corrosion and replace them if necessary.
  2.  

To install:
  1. With the pads installed as outlined in pad replacement, install the caliper and mounting bolts and torque to 38 ft. lbs. (51 Nm).
  2.  
  3. Connect the brake hose fitting and tighten to 33 ft. lbs. (45 Nm).
  4.  
  5. The remainder of installation is the reverse of the removal procedure.
  6.  

After installation is complete, properly bleed the brake system, as outlined in this section

OVERHAUL



See Figures 1, 2, 3, 4, 5, 6, 7 and 8

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  


CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

  1. The first method is as follows:
    1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    2.  
    3. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
    4.  

  2.  
  3. For the second method, you must rotate the piston to retract it from the caliper.
  4.  
  5. If equipped, remove the anti-rattle clip.
  6.  
  7. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
  8.  
  9. Remove the piston seals from the groove in the caliper bore.
  10.  



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Fig. Fig. 1: For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



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Fig. Fig. 2: Withdraw the piston from the caliper bore



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Fig. Fig. 3: On some vehicles, you must remove the anti-rattle clip



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Fig. Fig. 4: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 5: ... then remove the boot from the caliper housing, taking care not to score or damage the bore



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Fig. Fig. 6: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
  2.  
  3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
  4.  
  5. Use crocus cloth to polish out light corrosion from the piston and bore.
  6.  
  7. Clean all parts with denatured alcohol and dry with compressed air.
  8.  

To assemble:
  1. Lubricate and install the bleeder valve and cap.
  2.  
  3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
  4.  
  5. Lubricate the piston bore.
  6.  
  7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
  8.  
  9. Use a suitable driving tool to seat the boots in the housing.
  10.  
  11. Install the caliper in the vehicle.
  12.  
  13. Install the wheel and tire assembly, then carefully lower the vehicle.
  14.  
  15. Properly bleed the brake system.
  16.  



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Fig. Fig. 7: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing



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Fig. Fig. 8: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

 
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