GM Malibu/Cutlass 1997-2000

Brake Disc (Rotor)

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REMOVAL & INSTALLATION



  1. Remove 1 / 2 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Remove the brake caliper and pads, as outlined in this section.
  8.  
  9. If the rotor is to be resurfaced and replaced, mark the position of the rotor to hub and bearing assembly by marking a wheel stud and the corresponding hole in the rotor.
  10.  
  11. Remove the two knuckle bracket bolts from the back of the brake caliper bracket.
  12.  
  13. Remove the brake caliper bracket.
  14.  
  15. Lift the brake rotor off the hub and bearing assembly.
  16.  



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Fig. Remove the two knuckle bracket bolts from the back of the brake caliper bracket . . .



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Fig. . . . then remove the brake caliper bracket . . .



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Fig. . . . and lift off the brake rotor

To install:

  1. Install the brake rotor on the hub and bearing assembly. If replacing the rotor after resurfacing, line up the rotor-to-hub matchmarks.
  2.  
  3. Install two lug nuts to the studs to hold the rotor flat against the hub.
  4.  
  5. Install the brake caliper bracket and the two bracket bolts.
  6.  
  7. Reinstall the brake caliper and pads. Refer to the procedures as outlined in this section.
  8.  
  9. Install the wheel and tire assembly, then carefully lower the vehicle.
  10.  

INSPECTION



Check the disc brake rotor for scoring, cracks or other damage. Rotor run-out should be measured while the rotor is installed, while rotor thickness/thickness variation may be checked with the rotor installed or removed. Use a dial gauge to check rotor run-out. Check the rotor thickness to make sure it is greater than minimum thickness and check for thickness variations using a caliper micrometer.

Thickness Variation


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Fig. Check brake rotor thickness in several places around the rotor

  1. Measure the thickness at four or more points on the rotor. Make all measurements at the same distance in from the edge of the rotor. Use a micrometer calibrated in ten-thousandths of an inch.
  2.  
  3. A rotor that varies in thickness by more than 0.0005 in. (0.013mm) can cause pedal pulsation and/or front end vibration during brake applications. A rotor that does not meet these specifications should be resurfaced to specifications or replaced.
  4.  

Lateral Run-out


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Fig. Use the lug nuts to secure the rotor to the hub when checking rotor run-out

  1. Remove the wheel and tire assembly.
  2.  
  3. Fasten the lug nuts to retain the rotor.
  4.  
  5. Secure a dial indicator to the steering knuckle so the indicator button contacts the rotor at about 0.5 in. (13mm) from the outer edge of the rotor.
  6.  
  7. Set the dial indicator to zero.
  8.  
  9. Turn the wheel one complete revolution and observe the total indicated run-out.
  10.  
  11. If the run-out exceeds 0.003 in. (0.08mm), resurface or replace the rotor.
  12.  

 
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