GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Brake Caliper

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REMOVAL & INSTALLATION



1988-93 Vehicles

See Figure 1



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Fig. Fig. 1: If the caliper is not being removed, suspend it from the body with a piece of wire

  1. Remove about 2 / 3 of the brake fluid from the reservoir with a clean syringe or baster type utensil.
  2.  
  3. Raise and safely support the vehicle with jackstands.
  4.  
  5. Remove the rear wheel and tire assembly, then reinstall two lug nuts to retain the rotor.
  6.  
  7. Remove the brake shield assembly.
  8.  
  9. Loosen the tension on the parking brake cable at the equalizer.
  10.  
  11. Remove the parking cable and return spring from the lever.
  12.  
  13. Hold the cable lever and remove the locknut, lever and seal.
  14.  
  15. Push the piston into the caliper bore using two adjustable pliers over the inboard pad tabs.
  16.  

Do NOT allow pliers to contact the actuator screw. Protect the piston so the contact surface does not get damaged.

  1. Reinstall the lever seal with the sealing bead against the caliper housing, lever and locknut.
  2.  
  3. Remove and plug the brake hose inlet fitting only if the caliper is going to be removed from the vehicle.
  4.  
  5. Remove the bolt and bracket to gain access to the upper mounting bolt.
  6.  
  7. Unfasten the caliper mounting bolts, then pull the caliper from the rotor and suspend from the strut with a suitable piece of wire to prevent brake hose damage. Do NOT allow the caliper to hang from the brake hose.
  8.  

To install:
  1. Inspect all brake parts for damage and deterioration. Replace any parts if necessary.
  2.  
  3. Push the caliper sleeves inward.
  4.  
  5. Install the caliper to the mounting bracket. Tighten the mounting bolts to 92 ft. lbs. (125 Nm).
  6.  
  7. Install the bracket and bolt after the mounting bolts have been torqued.
  8.  
  9. Install the brake hose inlet with new copper washers if removed.
  10.  
  11. Remove the locknut, lever and seal. Lubricate the lever seal and lever shift.
  12.  
  13. Install the seal and lever with the lever facing down.
  14.  
  15. Hold the lever back against the stop and tighten the locknut to 35 ft. lbs. (47 Nm).
  16.  
  17. Install the return spring and parking brake cable. Adjust the cable as outlined in the Parking Brake Cable Adjustment procedures in this section.
  18.  
  19. Install the brake shield and rear wheel assembly.
  20.  
  21. Lower the vehicle.
  22.  
  23. Fill the brake reservoir with DOT 3 brake fluid.
  24.  
  25. Bleed the caliper, if it was removed from the vehicle. Refer to the Brake System Bleeding procedures in this section.
  26.  
  27. Inspect the brake system for fluid leaks.
  28.  
  29. Apply the brake pedal three times to seat the brake pads before moving the vehicle.
  30.  

1994-96 Vehicles

See Figures 2, 3 and 4



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Fig. Fig. 2: Caliper installation-1995 vehicle shown



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Fig. Fig. 3: When suspending the caliper, make sure to use a suitable piece of wire



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Fig. Fig. 4: Position the piston slots for caliper installation

  1. Raise and safely support the vehicle.
  2.  
  3. Matchmark the relationship of the wheel to the axle flange. Remove the wheel and tire assembly.
  4.  
  5. Reinstall two lug nuts to retain the rotor.
  6.  
  7. If the caliper is being removed from the vehicle for replacement or overhaul, perform the following:
    1. Disconnect the brake hose from the caliper. Plug the opening in the caliper and the brake hose to prevent fluid loss and system contamination.
    2.  
    3. Detach the parking brake cable by lifting up on one end of the cable spring clip to free the end of the cable from the lever.
    4.  

  8.  
  9. Remove the bolt and washer attaching the cable support brake to the caliper body assembly.
  10.  
  11. Remove the sleeve bolt, then remove the caliper body assembly. Pivot the caliper body up to clear the rotor and then slide it inboard OFF the pin sleeve.
  12.  
  13. If the caliper is being removed for shoe and lining replacement or to provide access to the support bracket, rotor of wheel brake components, hang the caliper from suspension using a suitable wire hook so as not to stretch or damage the brake hose or brake cable.
  14.  
  15. Inspect the pin boot, bolt boot and sleeve for cuts, tears or deterioration. If damaged, replace the boots.
  16.  

To install:
  1. Install the caliper assembly, as follows:
    1. If not replaced, remove the pin boot from the caliper body assembly and install the small end over the pint sleeve (installed on the caliper support) until the boot seats in the pin groove. This is to prevent cutting the pin boot when the sliding body assembly onto the pin sleeve.
    2.  
    3. Hold the caliper body assembly in position it was removed and start over the end of the pin sleeve. As the caliper body assembly approaches the pin boot, work the large end of the pin boot in the caliper body groove. Then push the caliper body fully onto the pin.
    4.  
    5. Pivot the caliper body assembly down, using care not to damage the piston boot on the inboard shoe. Compress the sleeve boot by hand as the caliper body move into position to prevent boot damage.
    6.  
    7. After the caliper body assembly is in position, recheck the installation of the pad clips. If necessary, use a small prytool to re-seat or center the pad clips on the support abutments.
    8.  

  2.  
  3. Install the sleeve bolt and tighten to 20 ft. lbs. (27 Nm).
  4.  
  5. Fasten the cable support bracket (with the cable attached) with the retaining bolts and washer. Tighten to 32 ft. lbs. (43 Nm).
  6.  
  7. If disconnected, attach the end of the parking brake cable to the parking brake lever by lifting up on the end of the cable spring clip and work the end of the parking brake cable into the notch in the lever.
  8.  
  9. Unplug and attach the brake hose, if it was disconnected.
  10.  
  11. Remove the two lug nuts retaining the rotor.
  12.  
  13. Install the wheel and tire assembly, aligning the marks made during removal.
  14.  
  15. Carefully lower the vehicle, then bleed the brake system if the brake hose was disconnected.
  16.  
  17. Firmly depress the brake pedal 3 times to seat the pads against the rotors.
  18.  

OVERHAUL



1988-93 Vehicles

See Figures 5 through 18



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Fig. Fig. 5: Unfasten the nut...



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Fig. Fig. 6: ... then remove the lever



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Fig. Fig. 7: Remove the lever seal and...



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Fig. Fig. 8: ... the anti-friction washer, if used



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Fig. Fig. 9: Rotate the actuator screw...



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Fig. Fig. 10: ... then remove the piston from the bore



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Fig. Fig. 11: Remove the balance spring



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Fig. Fig. 12: Remove the actuator screw by pressing on the thread end



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Fig. Fig. 13: Remove the shaft seal and thrust washer from the screw



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Fig. Fig. 14: Remove the boot, being careful not to scratch the caliper bore



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Fig. Fig. 15: Use ring pliers to compress the retainer...



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Fig. Fig. 16: ... then withdraw the retainer from the bore



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Fig. Fig. 17: Remove the piston locator...



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Fig. Fig. 18: ... then remove the piston seal from the caliper bore

  1. Remove the caliper assembly from the vehicle as previously outlined.
  2.  
  3. Remove the sleeve and bolt boots. Check the boots and bolts for damage and corrosion.
  4.  
  5. Remove the brake pad retainer from the end of the piston by rotating the retainer until the inside tabs line up with the notches in the piston.
  6.  
  7. Remove the locknut, lever, lever seal and anti-friction washer (if installed) from the caliper.
  8.  
  9. Remove the piston by using a wrench to rotate the actuator screw to work the piston out of the caliper bore.
  10.  
  11. Remove the balance spring and actuator screw.
  12.  
  13. Remove the shaft seal, thrust washer and boot.
  14.  
  15. Remove the retainer using ring pliers and a piston locator.
  16.  
  17. Remove the piston seal using a non-metallic seal pick.
  18.  
  19. Carefully remove the bleeder valve. If the valve breaks, the caliper should be replaced.
  20.  
  21. Inspect all parts for damage and replace if necessary.
  22.  
  23. Clean all parts in denatured alcohol and dry with compressed air.
  24.  
  25. Install the bleeder valve.
  26.  
  27. Install the bracket and bolt.
  28.  
  29. Lubricate the new piston seals with clean brake fluid and install into the caliper bore. Make sure they are not twisted.
  30.  
  31. Lubricate the piston locating tool J36627, do NOT install the piston.
  32.  
  33. Install the thrust washer on the actuator screw with the copper side towards the piston.
  34.  
  35. Lubricate the shaft seal and install it on the actuator screw.
  36.  
  37. Install the actuator into the piston assembly.
  38.  
  39. Install the balance spring and retainer into the piston.
  40.  
  41. After all the components are lubricated and installed into the piston, install the piston into the bore. Push the piston into the bore so that the locator is past the retainer groove in the caliper bore.
  42.  
  43. Install the retainer using retainer ring pliers.
  44.  
  45. Install the boot onto the piston with the inside lip of the boot in the piston groove and the boot fold is towards the end of the piston. Push the piston to the bottom of the bore.
  46.  
  47. Lubricate and install the lever seal over the end of the actuator screw.
  48.  
  49. Install the lever and rotate away from the stop slightly. Hold the lever while tightening the locknut to 32 ft. lbs. (44 Nm).
  50.  
  51. Install the pad retainer in the groove at the end of the piston.
  52.  
  53. Align the inside retainer tabs with the piston notches. Rotate the retainer so that the tabs enter the piston groove.
  54.  
  55. Lubricate with silicone grease and install the sleeve and bolt boots.
  56.  
  57. Install the caliper assembly and tighten the retaining bolts to 92 ft. lbs. (125 Nm).
  58.  
  59. Bleed the brake system as outlined in this section.
  60.  

1994-96 Vehicles

See Figure 19



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Fig. Fig. 19: Exploded view of the caliper assembly-1995 vehicle shown

  1. Remove the caliper from the vehicle, as outlined earlier, then place on a clean workbench.
  2.  

Pad the interior of the caliper assembly with clean shop towels to prevent damage to the piston assembly as it is removed.


CAUTION
Do NOT place fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in serious personal injury.

  1. Remove the piston from the caliper using compressed air into the caliper inlet hole. The piston will come out through the piston boots.
  2.  

Another method for piston removal is to use a spanner-type tool in the slots in the end of the piston to thread the piston assembly OFF the caliper.

  1. Remove the boot ring and piston boot. Use a small prytool to carefully pry up one end of the boot ring. Work the boot ring out of the caliper groove.
  2.  
  3. Use a small wooden or plastic tool to start the piston seal out of the caliper groove, then remove the seal.
  4.  
  5. Remove the bleeder valve cap and the bleeder valve.
  6.  
  7. If replacement is required, remove the lever return spring. Use a suitable prytool to disengage the return spring from the parking brake lever. Then unhook the spring from the stopper pin.
  8.  
  9. Remove the pin boot and the bolt boot from the caliper body.
  10.  
  11. Remove the bolt sleeve and sleeve boot from the caliper support.
  12.  
  13. Remove the pin bolt and pin sleeve from the caliper support.
  14.  
  15. Inspect all parts for damage, and replace as necessary. Clean all parts in denatured alcohol, then allow to dry thoroughly.
  16.  
  17. Lubricate the pin sleeve with silicone grease. Install the pin bolt and pin sleeve to the caliper support. Tighten the bolt to 20 ft. lbs. (27 Nm).
  18.  
  19. Lubricate the sleeve boot with silicone grease to ease installation. Compress the lip sleeve boot and push it all the way through the caliper body until the lip emerges and seats on the inboard face of the caliper ear.
  20.  
  21. Lubricate the sleeve with silicone grease to ease assembly. Push the bolt sleeve in through the lip end of the boot until the boot seats in the sleeve groove at the other end.
  22.  
  23. Install the bolt boot onto the caliper body.
  24.  
  25. Install the pin boot over the pin sleever (installed on the caliper support).
  26.  
  27. If removed, install a new lever return spring. Position the spring with the hook end around the stopper pin, then pry the other end of the spring over the lever.
  28.  
  29. Install the bleeder valve and tighten to 97 inch lbs. (11 Nm), then install the valve cap.
  30.  
  31. Lubricate a new piston seal with clean brake fluid, then install the seal. Make sure the seal is not twisted.
  32.  
  33. Install the piston boot onto the piston assembly.
  34.  
  35. Lubricate the piston assembly with clean brake fluid, then install the piston and boot into the bore of the caliper body assembly. Start the piston in by hand, then thread it into the bottom of the caliper bore using a suitable spanner-type tool into the slots in the end of the piston assembly.
  36.  
  37. Install the boot ring. Make sure the outside edge of the piston boot is smoothly seated in the counterbore or the caliper body assembly. Work the boot ring into the groove near the open end of the caliper bore, being careful not to pinch the piston boot between the boot ring and the caliper body.
  38.  
  39. After installing the ring, lift the inner edge of the boot next to the piston assembly and press out any trapped air. The boot must lie flat.
  40.  
  41. Install the caliper as outlined earlier in this section. Make sure to properly bleed the brake system.
  42.  

 
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