GM Corsica/Beretta 1988-1996 Repair Guide

Pads

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REMOVAL & INSTALLATION



1988-91 Vehicles

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

  1. Using a clean turkey baster or equivalent, siphon 2 / 3 of the brake fluid from the master cylinder reservoir and place in a suitable container.
  2.  
  3. Loosen the wheel lug nuts and raise the car. Remove the wheel and tire assembly, then reinstall two lug nuts to retain the rotor.
  4.  


WARNING
If you haven't removed some brake fluid from the master cylinder, it will overflow when the piston is retracted.

  1. Position a 12 in. (305mm) pair of adjustable pliers over the inboard brake shoe tab and the inboard caliper housing so that the caliper piston bottoms in its bore.
  2.  
  3. Remove the allen head caliper mounting bolts. Inspect the bolts for corrosion, and replace as necessary.
  4.  



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Fig. Fig. 1: For 1988-91 vehicles, use a large pair of adjustable pliers to compress the caliper piston for pad removal



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Fig. Fig. 2: Unfasten the caliper mounting bolts - 1988-91 vehicles

  1. Remove the caliper from the steering knuckle and suspend it from the body of the car with a length of wire. Do NOT allow the caliper to hang by its hose.
  2.  
  3. Use a 12 in. (305mm) pair of adjustable pliers to straighten the bent over shoe tabs, then remove the outboard shoe and lining from the caliper.
  4.  
  5. Remove the inboard shoe and lining from the caliper.
  6.  



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Fig. Fig. 3: Exploded view of the caliper, brake pads and related components - 1988-91 vehicles

  1. Remove the rubber bushings from the mounting bolt holes.
  2.  

To install:
  1. Install new bushings and lubricate with a light coating of silicone grease before installation. These bushings must always be replaced when the pads are replaced. They are usually included in the pad replacement kits.
  2.  



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Fig. Fig. 4: Before installation, lubricate the caliper bushing cavity with silicone grease - 1988-91 vehicles

  1. Install the retainer spring on the inboard pad. A new spring should be included in the pad replacement. On some models the spring is already staked to the inboard shoe.
  2.  
  3. Install the inboard shoe by snapping the retainer spring into the piston ID. The shoe must lay flat against the piston.
  4.  



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Fig. Fig. 5: The inboard shoe and lining assembly has a retaining spring attached to the back



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Fig. Fig. 6: Snap the retainer spring on the inboard shoe into the caliper piston and make sure the shoe lies flat against the piston

  1. Install the outboard pad into the caliper with the wear sensor at the leading edge of the shoe during forward wheel rotation. The back of the shoe must lay flat against the caliper.
  2.  



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Fig. Fig. 7: Installation of the outboard shoe and lining assembly - 1988-91 vehicles

  1. Install the caliper and tighten the mounting bolts to 38 ft. lbs. (51 Nm). Install the boots securely.
  2.  
  3. Partially lower the vehicle in order to apply the brake pedal at least three times to seat the linings.
  4.  
  5. Pry on the outboard shoe with a large flat-bladed tool between the outboard shoe flange and the hat section of the rotor. Keep the tool wedged in place for the following step.
  6.  
  7. Have an assistant apply moderate force on the brake pedal and clinch the outboard shoe tabs. The outboard shoe should be locked tightly in position.
  8.  



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Fig. Fig. 8: With an assistant depressing the brake pedal, you must clinch the outboard shoe tabs so they are locked tightly in position

  1. Install the wheel and tire assembly, then carefully lower the car.
  2.  
  3. Fill the master cylinder to its proper level with fresh brake fluid meeting DOT 3 specifications. Since the brake hose wasn't disconnected, it isn't really necessary to bleed the brakes, although most mechanics do this as a matter of course.
  4.  

1992-96 Vehicles

See Figures 9, 10, 11, 12, 13, 14, 15 and 16

  1. Siphon 2 / 3 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Loosen the wheel lug nuts, then raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly, then reinstall two wheel nuts to retain the rotor.
  6.  
  7. You must push the piston into the caliper bore to provide clearance between the linings and rotors as follows:
    1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe.
    2.  
    3. Slowly tighten the C-clamp until the piston is pushed into the caliper bore enough to slide the caliper assembly off the rotor.
    4.  

  8.  
  9. Remove the mounting bolts and sleeve assemblies and remove the caliper from the rotor and knuckle. Suspend the caliper from the strut using a wire hook.
  10.  
  11. Use a suitable pry tool to disengage the buttons on the shoe from the holes in the caliper housing.
  12.  
  13. Remove the inboard shoe and lining.
  14.  



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Fig. Fig. 9: Use a large C-clamp to bottom the caliper piston out in it's bore



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Fig. Fig. 10: If you're not removing the caliper for replacement or overhaul, suspend it with a piece of wire from the strut



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Fig. Fig. 11: Unfasten the caliper-to-rotor mounting bolts located at the rear of the caliper ...



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Fig. Fig. 12: ... then lift the caliper assembly off the rotor for access to the brake pads



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Fig. Fig. 13: Disengage the retainers, then remove the outboard shoe and lining ...



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Fig. Fig. 14: ... then the inboard shoe and lining assembly from the brake caliper



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Fig. Fig. 15: Exploded view of the caliper, brake pads and related components - 1992-96 vehicles

To install:
  1. Place the C-clamp over the caliper housing and into the piston. Carefully tighten the piston into the caliper bore.
  2.  
  3. After bottoming the piston, lift the inner edge of the boot and press out any trapped air. the boot must lay flat.
  4.  
  5. Install the inboard shoe by snapping the retainer spring into the piston.
  6.  
  7. Install the outboard pad into the caliper with the wear sensor at the leading edge of the shoe during forward wheel rotation. The back of the shoe must lay flat against the caliper.
  8.  
  9. Install the caliper and tighten the mounting bolts to 38 ft. lbs. (51 Nm). Install the boots securely.
  10.  
  11. Apply the brake pedal at least three times to seat the linings.
  12.  
  13. Install the wheel and lower the car.
  14.  
  15. Fill the master cylinder to its proper level with fresh brake fluid meeting DOT 3 specifications. Since the brake hose wasn't disconnected, it isn't really necessary to bleed the brakes, although most mechanics do this as a matter of course.
  16.  



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Fig. Fig. 16: Snap the retainer spring into the piston to install the inboard shoe and lining



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Fig. Fig. 17: When installing the pads, make sure the back of the shoe lies flat against the caliper

INSPECTION



The pad thickness should be inspected every time that the tires are removed for rotation. The outer pad an be checked by looking in at each end, which is the point at which the highest rate of wear occurs. The inner pad can be checked by looking down through the inspection hole in the top of the caliper. If the thickness of the pad is worn to within 1 / 32 in. (0.8mm) of the rivet at either end of the pad, all the pads should be replaced. This is the factory recommended measurement; your state's automobile inspection laws may not agree with this.

Always replace all pads on both front wheels at the same time. Failure to do so will result in uneven braking action and premature wear.

 
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