Malibu 2001-2005

Brake Caliper

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Siphon 2 / 3 of the brake fluid out of the master cylinder.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special piston retracting tool.
  8.  
  9. Remove the brake hose from the caliper and discard the copper washers.
  10.  
  11. Plug the hose to prevent excessive fluid loss and possible fluid contamination.
  12.  
  13. Remove the caliper mounting bolts
  14.  
  15. If removing the rear caliper, remove the park brake cable from the caliper.
  16.  
  17. remove the caliper from the knuckle.
  18.  
  19. Remove the brake pads from the caliper, if the caliper is being replaced.
  20.  

To install:

  1. Inspect the condition of the caliper support for rust and corrosion that will hinder the travel of the caliper.
  2.  
  3. Inspect the caliper mounting hardware. New bolts are usually recommended.
  4.  
  5. Lubricate the mounting bushings and sleeves with silicone grease as required.
  6.  
  7. Install the brake pads in the caliper.
  8.  
  9. Install the caliper on the steering knuckle.
  10.  
  11. Install the mounting bolts and torque to 26 ft. lbs. (35 Nm).
  12.  
  13. If installing the rear caliper, install the park brake cable to the caliper.
  14.  
  15. Connect the brake hose to the caliper using new copper washers and torque the mounting bolt to 37 ft. lbs. (50 Nm).
  16.  
  17. Refill the master cylinder and bleed the brake system.
  18.  
  19. Install the tire and wheel assembly.
  20.  
  21. Verify correct brake operation.
  22.  


CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

  1. Inspect the fluid level in the brake master cylinder reservoir.
  2.  
  3. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  4.  
  5. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the tire and wheel assembly.
  10.  
  11. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.

    Click image to see an enlarged view

    Fig. Install a large C-clamp over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad

  12.  
  13. Install a large C-clamp over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  14.  
  15. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  16.  
  17. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. Remove the brake hose-to-caliper bolt (1) from the brake caliper and the brake hose (3) from the brake caliper

  18.  
  19. Remove the brake hose-to-caliper bolt from the brake caliper.
  20.  
  21. Remove the brake hose from the brake caliper.
  22.  
  23. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.

    Click image to see an enlarged view

    Fig. Remove the brake caliper guide pin bolts

  24.  
  25. Remove the brake caliper guide pin bolts.
  26.  
  27. Remove the brake caliper from the caliper bracket.
  28.  
  29. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

    Restricted caliper guide pin movement
     
    Looseness in the brake caliper mounting bracket
     
    Seized or binding caliper guide pins
     
    Split or torn boots
     

  30.  
  31. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  32.  

To install:

  1. Install the brake caliper to the brake caliper bracket.
  2.  
  3. Install the brake caliper guide pin bolts, and tighten the bolts to 26 ft. lbs. (35 Nm).
  4.  
  5. Remove the caps or plugs from the brake caliper opening and the brake hose.
    NOTE
    Do not reuse the copper brake hose gaskets.

  6.  
  7. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  8.  
  9. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper, and tighten the bolt to 37 ft. lbs. (50 Nm).
  10.  
  11. Bleed the hydraulic brake system.
  12.  
  13. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. With the engine OFF , gradually apply the brake pedal to approximately  2 / 3 of its travel distance.
  20.  
  21. Slowly release the brake pedal.
  22.  
  23. Wait 15 seconds, then repeat the steps until a firm brake pedal apply is obtained; this will properly seat the brake caliper piston and brake pads.
  24.  



Click image to see an enlarged view

Fig. Install a large C-clamp over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad

  1. Install a large C-clamp over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  2.  
  3. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  4.  
  5. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. Remove the brake hose-to-caliper bolt (1) from the brake caliper and the brake hose (3) from the brake caliper

  6.  
  7. Remove the brake hose-to-caliper bolt from the brake caliper.
  8.  
  9. Remove the brake hose from the brake caliper.
  10.  
  11. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.

    Click image to see an enlarged view

    Fig. Remove the brake caliper guide pin bolts

  12.  
  13. Remove the brake caliper guide pin bolts.
  14.  
  15. Remove the brake caliper from the caliper bracket.
  16.  
  17. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:

    Restricted caliper guide pin movement
     
    Looseness in the brake caliper mounting bracket
     
    Seized or binding caliper guide pins
     
    Split or torn boots
     

  18.  
  19. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  20.  

To install:

  1. Install the brake caliper to the brake caliper bracket.
  2.  
  3. Install the brake caliper guide pin bolts, and tighten the bolts to 26 ft. lbs. (35 Nm).
  4.  
  5. Remove the caps or plugs from the brake caliper opening and the brake hose.
    NOTE
    Do not reuse the copper brake hose gaskets.

  6.  
  7. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  8.  
  9. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper, and tighten the bolt to 37 ft. lbs. (50 Nm).
  10.  
  11. Bleed the hydraulic brake system.
  12.  
  13. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. With the engine OFF , gradually apply the brake pedal to approximately  2 / 3 of its travel distance.
  20.  
  21. Slowly release the brake pedal.
  22.  
  23. Wait 15 seconds, then repeat the steps until a firm brake pedal apply is obtained; this will properly seat the brake caliper piston and brake pads.
  24.  

 
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