ION 2006-2007

Brake Calipers


Removal & Installation

  1. Remove or disconnect the following:

    Front wheel. Hand-tighten the lug nuts on the studs to prevent the rotor from falling off.

  3. Install a C-clamp over the body of the caliper with the clamp ends against the rear of the caliper body and against the outboard pad. Tighten the clamp until the caliper piston is compressed enough to allow the caliper to be removed.

    Brake hose from the caliper and discard the 2 copper washers. Plug the openings to prevent system contamination or excessive fluid loss.
    Caliper bolts
    Caliper from the bracket
    Pin boots from the caliper support and inspect for damage


To install:

  1. Install or connect the following:

    Brake pads and clips to the caliper bracket, if removed

  3. Lubricate the pin boots and guide pins with silicone grease.
    Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.

    Pin boots, if removed
    Caliper onto the bracket and over the brake pads
    Caliper bolts through the caliper and torque to 27 ft. lbs. (34 Nm)

    Brake hose using 2 new copper washers. Torque the fitting bolt to 35 ft. lbs. (50 Nm).

  5. Properly bleed the hydraulic brake system.