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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1118 (Disc Brake System) >> Repair Instructions >> Brake Caliper Overhaul - Rear >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
    NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.
  1. Remove the rear brake caliper from the vehicle. Refer to Brake Caliper Replacement - Rear .
    2. CAUTION: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.
    NOTE: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.
  2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole.
    3. Fig 1: View Of Dust Boot Retaining Ring
    GM777640Courtesy of GENERAL MOTORS CORP.
  3. Remove the retaining ring that secures the dust boot to the caliper housing.
    4. Fig 2: Exploded View Of Brake Caliper
    GM779716Courtesy of GENERAL MOTORS CORP.
  4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal.
  5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal.
    6. IMPORTANT: Do not use abrasives to clean the brake caliper piston.
  6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.
  7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air.
  8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
  9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
  10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.
  11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist.
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