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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 Pads 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 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.
    Fig 1: Compressing Brake Caliper Piston
    GM142234Courtesy of GENERAL MOTORS CORP.
  8. Tighten the C-clamp evenly 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. Fully loosen the caliper bolts (1, 4) from the steering knuckle (3).
    Fig 2: Identifying Caliper Bolts
    GM142240Courtesy of GENERAL MOTORS CORP.
    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.
  11. Without disconnecting the hydraulic brake flexible hose, remove the caliper assembly (2) from the steering knuckle. Support the caliper with heavy mechanic's wire (1), or equivalent.
    Fig 3: Securing Brake Caliper Assembly
    GM142244Courtesy of GENERAL MOTORS CORP.
  12. Remove the brake pads from the caliper.
    Fig 4: View Of Disc Brake Pads
    GM927124Courtesy of GENERAL MOTORS CORP.
  13. Remove the disc brake caliper bolts (1) from the caliper assembly (3).
    Fig 5: View Of Brake Caliper Bolts
    GM142246Courtesy of GENERAL MOTORS CORP.
  14. Inspect the caliper bolts (1) for rust, corrosion and/or damage.
  15. If the bolts are rusty, corroded, and/or damaged, replace the bolts (1) and replace the bushings (2). Refer to Disc Brake Hardware Replacement .
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