Malibu 2001-2005

Brake Pads

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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 reservoir.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the caliper from the steering knuckle without disconnecting the brake hose. DO NOT allow the caliper to hang from the brake hose. Support the caliper with a piece of wire.
  8.  
  9. Remove the outboard pad by pushing in on the outside edge of the pad to release the mounting dowel from the hole in the caliper. When both dowels are unseated push the pad out the bottom of the caliper.
  10.  
  11. Remove the inboard pad from the caliper by pulling it out of the caliper.
  12.  

To install:

  1. Install the inboard pad in the caliper so the spring clip on the pad back engages in the caliper piston.
  2.  
  3. Install the outboard pad over the caliper end until the mounting dowels snap into the mounting holes in the caliper.
  4.  
  5. Install the caliper over the rotor onto the steering knuckle. Install the mounting bolts and sleeves and torque to 40 ft. lbs. (51 Nm).
  6.  
  7. Install the tire and wheel assembly.
  8.  
  9. Pump the brake pedal several times to seat the pads against the rotor before attempting to move the vehicle.
  10.  
  11. Check the master cylinder level and add fluid as necessary.
  12.  


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. Remove the brake caliper lower guide pin bolt (1)

  12.  
  13. Remove the brake caliper lower guide pin bolt.

    Click image to see an enlarged view

    Fig. Push the disc brake caliper piston into the caliper bore using an old inner disc brake pad and a disc brake piston installation tool

  14.  
  15. Push the disc brake caliper piston into the caliper bore using an old inner disc brake pad and a disc brake piston installation tool.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  16.  
  17. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire, or equivalent.

    Click image to see an enlarged view

    Fig. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire (1), or equivalent

  18.  
  19. Remove the brake pads from the caliper mounting bracket.

    Click image to see an enlarged view

    Fig. Remove the brake pad retainers (2) from the caliper bracket (1)

  20.  
  21. Remove the brake pad retainers from the caliper bracket.
  22.  
  23. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket, of any debris and corrosion.
  24.  
  25. 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
     

  26.  
  27. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  28.  

To install:

  1. Ensure the brake pad hardware mating surfaces are clean.
  2.  
  3. Install the brake pad retainers to the brake caliper bracket.
    NOTE
    The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position.

  4.  
  5. Install the brake pads to the caliper bracket.
  6.  
  7. Remove the support, and rotate the brake caliper into position over the disc brake pads and to the caliper mounting bracket.
  8.  
  9. Install the lower brake caliper guide pin bolt, and tighten the bolt to 26 ft. lbs. (35 Nm).
  10.  
  11. Remove the wheel nuts retaining the brake rotor to the hub.
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Lower the vehicle.
  16.  
  17. With the engine OFF , gradually apply the brake pedal approximately  2 / 3 of its travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then gradually apply the brake pedal approximately  2 / 3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Fill the master cylinder auxiliary reservoir to the proper level.
  24.  
  25. Burnish the pads and rotors.
  26.  



Click image to see an enlarged view

Fig. Remove the brake caliper lower guide pin bolt (1)

  1. Remove the brake caliper lower guide pin bolt.

    Click image to see an enlarged view

    Fig. Push the disc brake caliper piston into the caliper bore using an old inner disc brake pad and a disc brake piston installation tool

  2.  
  3. Push the disc brake caliper piston into the caliper bore using an old inner disc brake pad and a disc brake piston installation tool.
    NOTE
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  4.  
  5. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire, or equivalent.

    Click image to see an enlarged view

    Fig. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire (1), or equivalent

  6.  
  7. Remove the brake pads from the caliper mounting bracket.

    Click image to see an enlarged view

    Fig. Remove the brake pad retainers (2) from the caliper bracket (1)

  8.  
  9. Remove the brake pad retainers from the caliper bracket.
  10.  
  11. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket, of any debris and corrosion.
  12.  
  13. 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
     

  14.  
  15. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
  16.  

To install:

  1. Ensure the brake pad hardware mating surfaces are clean.
  2.  
  3. Install the brake pad retainers to the brake caliper bracket.
    NOTE
    The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position.

  4.  
  5. Install the brake pads to the caliper bracket.
  6.  
  7. Remove the support, and rotate the brake caliper into position over the disc brake pads and to the caliper mounting bracket.
  8.  
  9. Install the lower brake caliper guide pin bolt, and tighten the bolt to 26 ft. lbs. (35 Nm).
  10.  
  11. Remove the wheel nuts retaining the brake rotor to the hub.
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Lower the vehicle.
  16.  
  17. With the engine OFF , gradually apply the brake pedal approximately  2 / 3 of its travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then gradually apply the brake pedal approximately  2 / 3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Fill the master cylinder auxiliary reservoir to the proper level.
  24.  
  25. Burnish the pads and rotors.
  26.  

 
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