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. 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. Raise and suitably support the vehicle.
  6.  
  7. Remove the tire and wheel assembly.
  8.  
  9. 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 outboard brake pad.
  10.  
  11. 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.
  12.  
  13. Remove the C-clamp from the caliper.
  14.  
  15. Remove the lower brake caliper guide pin bolt.
    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. Pivot the brake caliper upward from the caliper bracket and support the caliper out of the way with heavy mechanic's wire or equivalent; ensure that there is no tension on the hydraulic brake flexible hose. Do NOT disconnect the hydraulic brake flexible hose from the caliper.

    Click image to see an enlarged view

    Fig. Remove the brake pads (1) from the brake caliper mounting bracket (3)

  18.  
  19. Remove the brake pads from the brake caliper mounting bracket.
  20.  
  21. Remove and the brake pad retainers from the brake caliper mounting bracket.
  22.  

To install:

  1. Inspect the following brake components for damage and corrosion:

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

  2.  
  3. Do not attempt to clean away any corrosion. If damaged or corroded replace the necessary components.
  4.  
  5. Inspect the brake caliper piston boot for deterioration, replace if damaged.

    Click image to see an enlarged view

    Fig. Use a piston installation tool in order to twist the brake caliper piston into the brake caliper bore

  6.  
  7. Use a piston installation tool in order to twist the brake caliper piston into the brake caliper bore.
  8.  
  9. Install the brake pad retainers to the brake caliper mounting bracket.
  10.  
  11. Install the brake pads to the brake caliper mounting bracket.
  12.  
  13. Pivot the brake caliper downward, over the brake pads and into the caliper bracket.
  14.  
  15. Install the brake caliper guide pin bolt to the brake caliper guide pin, and tighten the brake caliper guide pin bolt to 26 ft. lbs. (35 Nm).
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Lower the vehicle.
  20.  
  21. With the engine OFF , gradually apply the brake pedal to approximately  2 / 3 of its travel distance.
  22.  
  23. Slowly release the brake pedal.
  24.  
  25. Wait 15 seconds, then repeat steps 15 and 16 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads.
  26.  
  27. Fill the brake master cylinder reservoir to the proper level.
  28.  
  29. Apply and release the park brake pedal 4 times.
  30.  
  31. Burnish the pads and rotors.
  32.  



Click image to see an enlarged view

Fig. Remove the brake pads (1) from the brake caliper mounting bracket (3)

  1. Remove the brake pads from the brake caliper mounting bracket.
  2.  
  3. Remove and the brake pad retainers from the brake caliper mounting bracket.
  4.  

To install:

  1. Inspect the following brake components for damage and corrosion:

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

  2.  
  3. Do not attempt to clean away any corrosion. If damaged or corroded replace the necessary components.
  4.  
  5. Inspect the brake caliper piston boot for deterioration, replace if damaged.

    Click image to see an enlarged view

    Fig. Use a piston installation tool in order to twist the brake caliper piston into the brake caliper bore

  6.  
  7. Use a piston installation tool in order to twist the brake caliper piston into the brake caliper bore.
  8.  
  9. Install the brake pad retainers to the brake caliper mounting bracket.
  10.  
  11. Install the brake pads to the brake caliper mounting bracket.
  12.  
  13. Pivot the brake caliper downward, over the brake pads and into the caliper bracket.
  14.  
  15. Install the brake caliper guide pin bolt to the brake caliper guide pin, and tighten the brake caliper guide pin bolt to 26 ft. lbs. (35 Nm).
  16.  
  17. Install the tire and wheel assembly.
  18.  
  19. Lower the vehicle.
  20.  
  21. With the engine OFF , gradually apply the brake pedal to approximately  2 / 3 of its travel distance.
  22.  
  23. Slowly release the brake pedal.
  24.  
  25. Wait 15 seconds, then repeat steps 15 and 16 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads.
  26.  
  27. Fill the brake master cylinder reservoir to the proper level.
  28.  
  29. Apply and release the park brake pedal 4 times.
  30.  
  31. Burnish the pads and rotors.
  32.  

 
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