GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2004 🢒 GTO 🢒 Brakes 🢒 Disc Brakes 🢒 Front Brake Caliper Overhaul

Disassembly Procedure
  1. Remove the front brake caliper. Refer to Front Brake Caliper Replacement .

    2. Object Number: 1355226 Size: SH
  2. Use a wrench in order to prevent the guide pins (6,11) from rotating.
  3. Remove and discard the 2 guide pin bolts (7,9).
  4. Separate the caliper housing (10) from the bracket (1).
  5. Remove the 2 brake pads (16,17) and the 2 anti-rattle clips (18,19). Refer to Front Disc Brake Pads Replacement .
  6. Remove the 2 guide pins and the 2 guide pin boots (5,12) from the bracket.
  7. Separate the 2 guide pins from the 2 guide pin boots.
  8. Discard the 2 guide pin boots.

    9. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

    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.

    Notice: Use just enough air pressure to ease the piston out of the bore. You can damage a blown-out piston even with the padding.

  9. Insert a clean shop cloth into the caliper in order to catch the first piston.
  10. Apply compressed air to the caliper brake hose connector hole in order to remove the first piston.
  11. Use internal expanding snap ring pliers in order to grasp the inner wall of the second piston.
  12. Twist and pull the second piston out of the bore.
  13. Remove the 2 piston boots (2,15) from the pistons (3,14).
  14. Use a flat plastic tool in order to remove the seals (4,13) from the caliper. Discard the seals.
  15. Remove the bleeder valve cap.
  16. Remove the bleeder valve.

Inspection Procedure

    Object Number: 1355226 Size: SH
  1. Use denatured alcohol or an equivalent brake cleaner in order to clean all the metal parts (1,3,6,8,10,11,14,18,19).
  2. Use GM Vehicle Care® Brake and Clutch Fluid Super DOT-4, GM P/N 88958860, or an equivalent DOT-4 brake fluid, in order to clean the caliper piston boots (2,15).
  3. Use dry, unlubricated, compressed air in order to dry the components and clean the bores in the caliper housing.
  4. Inspect the guide pin bores for corrosion or wear. Replace the caliper assembly if damage is evident.
  5. Inspect the caliper piston bores for cracks, scoring, pitting, or corrosion. Replace the caliper assembly if damage is evident.
  6. Inspect the bracket (1) for damage. Replace the caliper assembly if damage is evident.
  7. Inspect the 2 guide pins (6,11) for corrosion or wear. Replace the 2 guide pins if damage is evident.
  8. Inspect the 2 caliper pistons (3,14) for abrasion, scoring, or corrosion. Replace the 2 caliper pistons if damage is evident.
  9. Inspect the 2 piston boots (2,15) for cracks, holes, or wear. Utilize the front caliper repair kit if damage is evident.

Assembly Procedure

    Object Number: 1355226 Size: SH
  1. Use GM Vehicle Care® Brake and Clutch Fluid Super DOT-4, GM P/N 88958860, or an equivalent DOT-4 brake fluid, in order to lubricate the following components:
    2. • The 2 caliper pistons (3,14)
    • The piston cylinder bores
    • The 2 piston boots (2,15)
    • The 2 NEW seals (4,13)
    • The 2 NEW guide pin boots (5,12)
  2. Complete the following procedure in order to install EACH piston:
    3. 2.1. Install a NEW seal to the inner groove of a cylinder bore.
    2.2. Ensure the seal is not twisted.
    2.3. Ensure the seal is fully seated in the seal groove.
    2.4. Install a piston boot over the end of a piston.
    2.5. Install a piston into a cylinder bore.
    2.6. Install a piston boot to a cylinder bore groove.
    2.7. Ensure the piston boot flange is squarely and firmly seated in the cylinder bore groove.
    2.8. Push the piston squarely into the cylinder bore until the piston is fully seated.
    2.9. Ensure the piston boot is fully seated in the piston groove and in the cylinder bore groove.
  3. Lubricate the guide pins (6,11) with Silicone Brake Lubricant, GM P/N 89021536, ACDelco P/N 89021537 (Canadian P/N 89021538), or equivalent.
  4. Install the guide pins to the bracket (1) WITHOUT the guide pin boots.
  5. Install the caliper housing (10) to the bracket.
  6. Use a wrench in order to prevent the guide pins from rotating.

    7. Notice: Refer to Fastener Notice in the Preface section.

  7. Install 2 NEW guide pin bolts (7,9).

    8. Tighten
    Tighten the bolts to 32 N·m (24 lb ft)

    Important: If any binding is evident, add more lubricant to the guide pins and replace the guide pin bolts.

  8. Verify the guide pins and the caliper housing slide easily in the bracket.
  9. Remove the bracket from the guide pins.
  10. Install 2 NEW guide pin boots (5,12) to the guide pins.
  11. Install the bracket to the guide pins.
  12. Complete the following procedure in order to install EACH guide pin boot:
    13. 12.1. Squeeze the guide pin boot in order to remove excess air.
    12.2. Install the guide pin boot to the guide pin groove.
    12.3. Install the guide pin boot to the bracket groove.
  13. Clean the 2 caliper piston contact surfaces with denatured alcohol or an equivalent brake cleaner.
  14. Install the 2 brake pads (16,17) and the 2 anti-rattle clips (18,19). Refer to Front Disc Brake Pads Replacement .
  15. Install the bleeder valve (8) and the valve cap to the caliper housing.
  16. Install the caliper to the vehicle and bleed the brake system. Refer to Front Brake Caliper Replacement .