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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 467 (Disc Brakes & Drum Brakes) >> Removal & Installation >> Front Brake Caliper >> Installation

Front Brake Caliper: Installation

WARNING: This page is about a different car, the 2002 GMC Safari and 2002 Chevrolet Astro. However, it is still accessible from the selected car via links, so may be relevant.
  1. If reusing brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol or equivalent.
  2. Dry brake caliper pin bolts using non-lubricated filtered air.
  3. Apply high temperature silicone brake lubricant to brake caliper pin bolts and retainers. DO NOT apply lubricant to brake pad hardware.
  4. Install bushings.
  5. On RWD models, install the sleeves.
  6. On all models, install brake pads. See FRONT BRAKE PADS .
  7. Install caliper assembly.
  8. Install mounting bolts. Tighten to specification. See TORQUE SPECIFICATIONS .
    9. NOTE: Install NEW copper brake hose gaskets.
  9. Install the brake hose bolt and NEW copper brake hose gaskets to the brake hose.
  10. Install brake hose-to-caliper bolt to brake caliper. Tighten to specification. See TORQUE SPECIFICATIONS .
  11. Remove wheel lug nut securing the rotor to hub.
  12. Measure clearance between caliper and steering knuckle. Measure clearance at each end of the caliper individually and then add measurements together. The total should be .010-.024" (.26-.60 mm).
    • If total clearance between caliper and steering knuckle is less than .010" (.26 mm), file the steering knuckle equally on each side until proper clearance is obtained.
    • If total clearance between caliper and steering knuckle is more than .024" (.60 mm), inspect brake caliper and steering knuckle for damage and replace as needed.
  13. Install wheels. Lower vehicle. Fill master cylinder to proper level with clean brake fluid. Bleed brake system. See BLEEDING BRAKE SYSTEM .
  14. Lower vehicle.
  15. Fill master cylinder to proper level with clean brake fluid.
  16. Bleed brake system. See BLEEDING BRAKE SYSTEM .
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