GM Malibu/Cutlass 1997-2000

Brake Pads

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REMOVAL & INSTALLATION




CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  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. Reinstall two wheel nuts in order to retain the rotor to the hub and bearing assembly.
  8.  


NOTE
If installing new disc brake pads, use a C-clamp or similar tool to push the caliper piston into the caliper bore. This will allow room for the new pads. Even if the pads are not being replaced, it is still recommended to push the piston back slightly in order to provide clearance between the linings and the rotor.

  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 C-clamp until the piston is pushed into the caliper bore.
  4.  
  5. Brace the sleeves with a wrench and remove the guide pin bolts.
  6.  
  7. Lift the caliper off of the caliper bracket and support it using mechanics wire or another suitable device to prevent damage to the brake hose.
  8.  



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Fig. Brace the guide pin sleeves with a wrench, then remove the guide pin bolts



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Fig. Support the caliper using mechanic's wire or another suitable device to prevent damage to the brake hose

  1. Remove the inboard and outboard pads by pulling the top of the pads away from the rotor.
  2.  



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Fig. Remove the inboard and outboard pads by pulling the top of the pads away from the rotor


NOTE
Carefully inspect front disc brake hardware whenever possible. If signs of contact wear, rust, or corrosion is evident, replace all hardware.



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Fig. Carefully inspect the guide pin bolts and the bolt sleeves

  1. Inspect the front disc brake hardware as follows and replace as necessary:
    1. Inspect the mounting guide pin bolts and sleeves for corrosion, excess dirt, or signs of metal fatigue.
    2.  
    3. Inspect the boots for cuts or nicks.
    4.  
    5. Inspect the anti-rattle clips and shims for contact wear or rust.
    6.  

  2.  

To install:

  1. Liberally coat the inside diameter of the mounting guide sleeve bores using silicone grease.
  2.  
  3. Coat the back of the new pads with a suitable anti-squeal lubricant.
  4.  
  5. Place the inboard disc brake pad into position on the caliper bracket. Make sure the wear indicator faces downward.
  6.  
  7. Place the outboard disc brake pad into position on the caliper bracket.
  8.  
  9. Install the caliper, over the rotor and pads, onto the caliper bracket.
  10.  
  11. Install the mounting guide pin bolts and sleeve assemblies. Tighten the mounting bolt 23 ft. lbs. (31 Nm).
  12.  
  13. Remove the two wheel nuts previously installed.
  14.  
  15. Reinstall the wheel and tire assembly. Torque the lug nuts to 100 ft. lbs. (140 Nm).
  16.  
  17. Lower the vehicle.
  18.  
  19. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle.
  20.  
  21. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary.
  22.  
  23. Road test the vehicle and check for proper brake system operation.
  24.  

INSPECTION



  1. Raise and support the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Looking down through the inspection hole on the top of the caliper, inspect the brake pads. If the lining is worn down to within 1 / 32 in. (0.8mm) of the shoe, the pads must be replaced.
  6.  


NOTE
This figure may disagree with your state's automobile inspection laws.

If the brake lining is soaked with brake fluid or grease, it must be replaced. If this is the case, the brake rotor should be sanded with crocus cloth to remove all traces of brake fluid, and the calipers and lines should be inspected for leaks.

If the lining is chipped, cracked, or otherwise damaged, it must be replaced with a new lining.


NOTE
Always replace the brake linings in sets of two on both ends of the axle. Never replace just one pad, or both on one side and not the other. When replacing the brakes, it is a good idea to replace one side at a time so that you always have an example to refer to if you get confused during reassembly.

 
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