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. 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 suitably support the vehicle.
  8.  
  9. Remove the tire and wheel assembly.
  10.  
  11. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  12.  
  13. 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.
  14.  
  15. Remove the C-clamp from the caliper.

    Click image to see an enlarged view

    Fig. Remove the brake hose to caliper bolt from the brake caliper

  16.  
  17. Remove the brake hose to caliper bolt from the brake caliper.
  18.  
  19. Remove the brake hose from the brake caliper.
  20.  
  21. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  22.  
  23. 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 2 brake caliper pin bolts

  24.  
  25. Remove the 2 brake caliper pin bolts.

    Click image to see an enlarged view

    Fig. Remove the park brake cable from the caliper

  26.  
  27. Remove the park brake cable from the caliper.
  28.  
  29. Remove the brake caliper from the brake caliper bracket.
  30.  

To install:

  1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots.
  2.  
  3. Install the brake caliper to the brake caliper bracket.
  4.  
  5. Install the 2 brake caliper pin bolts, and tighten the brake caliper pin bolts to 26 ft. lbs. (35 Nm).
  6.  
  7. Install the park brake cable to the caliper.
  8.  
  9. Remove the caps or plugs from the brake caliper opening and the brake hose.
    NOTE
    DO NOT reuse the copper brake hose gaskets.

  10.  
  11. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  12.  
  13. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper, and tighten the brake caliper bolt to 37 ft. lbs. (50 Nm).
  14.  
  15. Bleed the hydraulic brake system.
  16.  
  17. With the engine OFF , gradually apply the brake pedal to approximately 2 / 3 of its travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then repeat steps 11 and  12 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Install the tire and wheel assembly.
  24.  
  25. Lower the vehicle.
  26.  
  27. Apply and release the park brake pedal 4 times.
  28.  



Click image to see an enlarged view

Fig. Remove the brake hose to caliper bolt from the brake caliper

  1. Remove the brake hose to caliper bolt from the brake caliper.
  2.  
  3. Remove the brake hose from the brake caliper.
  4.  
  5. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  6.  
  7. 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 2 brake caliper pin bolts

  8.  
  9. Remove the 2 brake caliper pin bolts.

    Click image to see an enlarged view

    Fig. Remove the park brake cable from the caliper

  10.  
  11. Remove the park brake cable from the caliper.
  12.  
  13. Remove the brake caliper from the brake caliper bracket.
  14.  

To install:

  1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots.
  2.  
  3. Install the brake caliper to the brake caliper bracket.
  4.  
  5. Install the 2 brake caliper pin bolts, and tighten the brake caliper pin bolts to 26 ft. lbs. (35 Nm).
  6.  
  7. Install the park brake cable to the caliper.
  8.  
  9. Remove the caps or plugs from the brake caliper opening and the brake hose.
    NOTE
    DO NOT reuse the copper brake hose gaskets.

  10.  
  11. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  12.  
  13. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper, and tighten the brake caliper bolt to 37 ft. lbs. (50 Nm).
  14.  
  15. Bleed the hydraulic brake system.
  16.  
  17. With the engine OFF , gradually apply the brake pedal to approximately 2 / 3 of its travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then repeat steps 11 and  12 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Install the tire and wheel assembly.
  24.  
  25. Lower the vehicle.
  26.  
  27. Apply and release the park brake pedal 4 times.
  28.  

 
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