Malibu, Malibu MAXX 2006-2008

Brake Calipers

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Removal & Installation





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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.

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    Fig. Remove the 2 brake caliper pin bolts

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

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    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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