GM Grand Am/Achieva/Calais/Skylark/Somerset 1985-98

Brake Caliper

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

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Fig. Fig. 1: After the caliper has been compressed with a C-clamp, remove the banjo bolt that secures the hydraulic line to the caliper



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Fig. Fig. 2: Then unbolt the caliper from the steering knuckle



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Fig. Fig. 3: When installing the caliper, make sure to lubricate the mounting bolts and bushings

  1. Using a clean turkey baster or equivalent, remove about 2 /3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel.
  6.  
  7. Push the piston into the caliper bore to provide clearance between the brake pads and the rotor as follows:
    1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.
    2.  
    3. Slowly tighten the clamp until the piston is pushed into the caliper bore enough slide the caliper off of the rotor.
    4.  

  8.  
  9. Unfasten the banjo bolt attaching the brake hose fitting, then plug the exposed fitting to prevent contamination.
  10.  
  11. Unfasten the caliper mounting bolt and sleeve assemblies. Some vehicles have a rubber cap over the bolts, which must be removed first.
  12.  
  13. Lift the caliper off of the rotor.
  14.  
  15. Inspect the mounting bolts, sleeves and bushings for damage and replace as necessary.
  16.  

To install:
  1. Liberally coat the inside of the bushings with silicone grease.
  2.  
  3. Position the caliper over the rotor into the knuckle, then fasten the mounting bolt and sleeve assemblies. Tighten to 38 ft. lbs. (51 Nm).
  4.  
  5. Using new copper washers, install the banjo bolt in the brake hose fitting and attach it to the caliper. Tighten the banjo bolt to 32 ft. lbs. (44 Nm).
  6.  
  7. Bleed the brakes as necessary.
  8.  
  9. Install the wheel.
  10.  

OVERHAUL



See Figures 4 through 10

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Fig. Fig. 4: 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. 5: Withdraw the piston from the caliper bore



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Fig. Fig. 6: On some vehicles, you must remove the anti-rattle clip



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Fig. Fig. 7: Use a prytool to carefully pry around the edge of the boot ...



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Fig. Fig. 8: ... then remove the boot from the caliper housing, taking care not to score or damage the bore



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Fig. Fig. 9: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore



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Fig. Fig. 10: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

  1. Remove the caliper from the vehicle. Place the caliper on a workbench.
  2.  
  3. Remove the bushings. Inspect for cuts and nicks. Replace as necessary.
  4.  
  5. Stuff a shop towel or a block of wood into the caliper to catch the piston and apply compressed air to the inlet hole.
  6.  


CAUTION
DO NOT apply too much air pressure to the bore, for the piston may jump out, causing damage to the piston and/or the operator. Be absolutely sure to keep your fingers away from the piston while air is being applied.

  1. Remove and discard the piston boot and seal. Be careful not to scratch the bore. Use of a metal tool is NOT recommended when removing the boot and the seal because of the possibility of scoring and damaging the bore.
  2.  
  3. Inspect the piston for scoring, nicks, corrosion and worn chrome plating. Replace as necessary.
  4.  
  5. Remove the boot from the caliper housing bolt.
  6.  
  7. Remove the bleeder screw and its rubber cap.
  8.  
  9. Inspect the housing bore and seal groove for scoring, nicks, corrosion and wear. Crocus cloth can be used to polish out light corrosion.
  10.  
  11. Remove the bleeder valve and bleeder valve cap.
  12.  

To install:
  1. Install the bleeder valve and bleeder valve cap into the caliper.
  2.  
  3. Lubricate the piston, caliper and seal with clean brake fluid.
  4.  
  5. Install the piston seal into the caliper seal groove. Make sure it is not twisted in the caliper bore groove.
  6.  
  7. Bottom the piston into the bore, then secure the boot using J 29077 or an equivalent piston seal installer tool.
  8.  
  9. Lubricate the beveled end of the bushings with silicone grease. Pinch the bushing and install the beveled end first. Push the bushing through the housing mounting bore.
  10.  
  11. Install the pads into the caliper assembly.
  12.  
  13. Install the caliper onto the steering knuckle, then properly bleed the hydraulic brake system.
  14.  

 
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