Montana SV6 (2006), Relay, Terraza, Uplander (2005-2007)

Brake Calipers


Removal & Installation

Click image to see an enlarged view

Fig. Exploded view of front brake caliper assembly

  1. Before servicing the vehicle, refer to the Precautions Section.
    Inspect the fluid level in the brake master cylinder reservoir. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.

  3. Remove the wheel, marking the location of the wheel to the hub prior to removal. Mark the individual location of all retainers as they are removed.
  5. Install two wheel lug nuts to retain the rotor to the hub
  7. Install a large C-clamp over the top of the brake caliper and against the back of the outboard brake pad
  9. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor
  11. Remove or disconnect the following:
    Inspect the brake caliper pin boots, if the caliper pin boots are damaged, inspect the caliper pins for corrosion or damage. If corrosion is found on the brake caliper pin shaft, replace the brake caliper pin and the brake caliper pin boot. Do not attempt to polish away the corrosion.

    Brake hose bolt
    Brake hose from the brake caliper
    Discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end
    Plug the openings in the brake caliper and the brake hose in order to prevent brake fluid loss and contamination.
    Clean off any dirt or corrosion on the brake caliper near the brake hose fitting
    Brake caliper bolts
    Brake caliper from the brake caliper bracket


To install:

  1. Ensure that the caliper bolt boots are properly installed.
  3. Install or connect the following:
    Install NEW copper brake hose gaskets

    Caliper to the caliper bracket
    Caliper bolts and tighten the bolts to 40 ft. lbs. (54 Nm)

    Brake hose bolt and the NEW copper brake hose gaskets to the brake hose
    Brake hose bolt to the brake caliper and tighten the bolt to 40 ft. lbs. (54 Nm)

  5. Install the tire and wheel assembly. Tighten the lug nuts to 100 ft. lbs. (140 Nm) in a criss-cross pattern, after aligning the wheel hub with the reference mark and holes as shown in appropriate illustration.
  7. Refill the master cylinder to the correct level. Bleed the brake system.