Malibu 2001-2005

Brake Disc (Rotor)

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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. Check to be sure that the park brake is released.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
    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.


    NOTE
    Do NOT disconnect the hydraulic brake flexible hose from the caliper.

  6.  
  7. Remove the brake caliper mounting bracket and caliper as an assembly from the suspension knuckle and support the assembly with heavy mechanic's wire, or equivalent.
  8.  
  9. Ensure that there is no tension on the hydraulic brake flexible hose.
  10.  
  11. Matchmark the position of the brake rotor to the wheel studs.
  12.  
  13. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward.

    Click image to see an enlarged view

    Fig. The removal and installation of the brake rotor

  14.  

To install:


NOTE
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Using the J42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
  8.  
  9. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes.
  10.  
  11. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications.
  12.  
  13. Install the brake caliper mounting bracket an caliper as an assembly to the suspension knuckle.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors.
  20.  



Click image to see an enlarged view

Fig. The removal and installation of the brake rotor

To install:


NOTE
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Using the J42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
  8.  
  9. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled Lateral Runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes.
  10.  
  11. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications.
  12.  
  13. Install the brake caliper mounting bracket an caliper as an assembly to the suspension knuckle.
  14.  
  15. Install the tire and wheel assembly.
  16.  
  17. Lower the vehicle.
  18.  
  19. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors.
  20.  

 
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