Front Brake Caliper Replacement J65, JL9

Caution: Refer to Brake Dust Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

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, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the front tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.



6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
8. Remove the C-clamp from the caliper.



9. Remove the brake hose-to-caliper bolt (1) from the caliper.

Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.

10. Plug the opening in the front brake hose (2) to prevent excessive brake fluid loss and contamination.

Important: Note the location of the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design.




11. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.
12. Remove the caliper (2) from the rotor and the caliper bracket (3).
13. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots. Refer to Front Disc Brake Hardware Replacement .



14. Inspect the caliper bolts (1) for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts (1) when installing the caliper.

1. If reusing the brake caliper pin bolts, wipe away any debris and old lubricant with a with a clean shop cloth.
2. Apply lubricant, GM P/N 18047666, or equivalent, to the brake caliper pin bolts. Apply a thin layer to the pin bushing (2) and to the caliper pin bolt shank (3, 4). Ensure that there is not a buildup of excess lubricant at the end of the leading caliper pin (1), in front of the bushing.



3. Install the caliper (2) over the rotor and onto the caliper bracket (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Important: The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.

4. Install the caliper pin bolts (1). The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Ensure that the bolt boots fit securely in the groove of the caliper pin bolts. If the boots are damaged, they must be replaced.

Tighten
Tighten the bolts to 95 N·m (70 lb ft).





Important: Install NEW copper brake hose gaskets.

5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
6. Install the brake hose-to-caliper bolt to the brake caliper.

Tighten
Tighten the bolt to 54 N·m (40 lb ft).

7. Remove the 2 wheel lug nuts retaining the rotor to the hub.
8. Install the front tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
9. Lower the vehicle.
10. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
12. Inspect the hydraulic brake system for brake fluid leaks.

Front Brake Caliper Replacement Z7U