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Brake Caliper (Front)

  1. Replace all the components included in repair kit for the brake caliper.
  2. Lubricate rubber parts with new DOT-3 brake fluid to make assembly easier.
  3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system.
  4. The torque values specified are for dry, non-lubricated fasteners.
  5. Perform service operations on a clean bench, free from all mineral oil materials.
  6. Remove brake caliper from vehicle. See BRAKE CALIPER (FRONT)  under REMOVAL & INSTALLATION.
  7. Drain brake fluid from brake caliper.
  8. Place a 1" (25 mm) block of wood between the caliper and piston.
  9. Install a large C-clamp over the body of the brake caliper with C-clamp ends against the rear of the caliper body and against the block of wood.
  10. Carefully remove brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole.
  11. Remove C-clamp from caliper.
  12. Remove block of wood from caliper.
  13. Install clean cloths to pad the interior of the caliper housing between the remaining caliper piston and caliper body.
  14. To cover the open caliper bore place a 1" (25 mm) block of wood between the caliper body and brake caliper dust boot seal.
  15. 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 block of wood.
  16. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake caliper inlet hole.
  17. Remove C-clamp from caliper.
  18. Remove block of wood from caliper.
    19. NOTE: Care must be used when removing piston boot and seal from caliper. Use a small plastic or wood tool for removal. Do not use a metal tool because it may damage the caliper bore or seal groove.
  19. Remove piston boots from brake caliper.
  20. Remove piston seals from brake caliper.
  21. Remove brake caliper bleeder valve and cap from brake caliper.
    22. NOTE: DO NOT use abrasives to clean brake caliper piston.
  22. Clean brake caliper piston bore and seal counterbore and caliper piston with denatured alcohol.
  23. Dry caliper piston bores and counter bores and piston with non-lubricated, filtered air.
  24. Inspect piston for scoring, nicks, cracks, wear, or corrosion. Replace if any damage is found. Inspect caliper bore for scoring, nicks, cracks, wear, or corrosion. Use crocus cloth to polish out light corrosion. Otherwise, replace caliper. Do not hone caliper bore. Inspect seal groove in caliper bore for nicks or burrs. If found, replace caliper.
  25. Install brake caliper bleeder valve and bleeder valve cap into the brake caliper.
  26. Lubricate NEW piston seal with DOT-3 brake fluid from a clean, sealed brake fluid container.
  27. Install the lubricated, new piston seals into the caliper bores.
  28. Install caliper piston into the caliper bore.
  29. Install new piston dust boot seal over the piston.
  30. Using the Brake Caliper Piston Boot Seal Installer (J-45515), fully seat piston dust boot seal in the caliper.
  31. Install brake caliper to vehicle.
Fig 1: Exploded View Of Front Caliper Assembly
G00277775Courtesy of GENERAL MOTORS CORP.
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