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Home >> Chevrolet >> 2001 >> Cavalier LS, 2.2 4 >> Repair and Diagnosis >> External Pages >> Different car >> Section 246 (Disc Brake System) >> Repair Instructions >> Brake Caliper Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the fluid level in the brake master cylinder reservoir.
  2. 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.
  3. 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.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    Fig 1: Identifying Compressed Brake Caliper
    GM142234Courtesy of GENERAL MOTORS CORP.
  8. 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.
  9. Remove the C-clamp from the caliper.
  10. Clean all dirt and foreign material from the brake hose end.
  11. Remove the brake hose-to-caliper bolt (1) from the brake caliper.
  12. Remove the brake hose (3) from the brake caliper.
  13. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3).
  14. Cap or plug the opening in the brake caliper and the brake hose (3) to prevent fluid loss and contamination.
    Fig 2: Exploded View Of Brake Hose Fittings
    GM927122Courtesy of GENERAL MOTORS CORP.
  15. Fully loosen the caliper bolts from the steering knuckle.
  16. Remove the brake caliper from the steering knuckle.
  17. Remove the brake pads from the caliper.
    Fig 3: View Of Disc Brake Pads
    GM927124Courtesy of GENERAL MOTORS CORP.
  18. Remove the disc brake caliper bolts (1) from the caliper assembly (3).
  19. Inspect the caliper bolts (1) for rust, corrosion and/or damage.
  20. If the bolts are rusty, corroded, and/or damaged, replace the bolts (1) and replace the bushings (2). Refer to Disc Brake Hardware Replacement .
    Fig 4: View Of Brake Caliper Bolts
    GM142246Courtesy of GENERAL MOTORS CORP.
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