For 1990-2009 cars

## Front Brake Caliper Replacement Bendix

### Removal Procedure

Caution: Refer to Vehicle Lifting and Jacking Notice in the Preface section.

1. Apply the parking brake.
2. Block the wheels.

Important:

• | Do not completely drain the master cylinder reservoir.

• | Drain the fluid from the brake caliper bleeder valve.

• | Drain the fluid into a suitable container. Discard the fluid.

3. Remove about 2/3 of the brake fluid from the master cylinder reservoir.
4. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Remove the brake caliper retainer bolt (1).
7. Remove the brake caliper retainer (3) and the brake caliper spring (2) using a brass punch.
8. Compress the pistons, using one of the following methods:

• | Using a C-clamp between the inner brake caliper housing and the outer brake pad.

• | Use screwdrivers in order to pry between the outer brake caliper housing and the outer brake pad.

9. While compressing the pistons, watch the reservoir for possible brake fluid overflow. The inner brake pad may stay on the brake caliper mounting plate (Bendix® caliper).
10. Remove the wheel speed sensor.
11. Disconnect the brake hose.
12. Cap or tape the brake hose fitting in order to prevent contamination.

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

13. Remove the front brake hose.
14. Remove the front brake caliper.

### Inspection Procedure

Caution: Avoid taking the following actions when you service wheel brake parts:

• | Do not grind brake linings.

• | Do not sand brake linings.

• | Do not clean wheel brake parts with a dry brush or with compressed air.

Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.
1. Clean the area around the brake hose on the brake caliper. Use Brake Parts cleaner GM P/N 12345754 or the equivalent.
2. Inspect the support rail surfaces on the brake caliper.
3. Inspect the support rail surfaces on the brake caliper mounting plate.
4. Inspect the heat shields. If the heat shields are loose, replace the shields.

### Installation Procedure

1. Clean the support rail surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the support rail surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.
3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper support rail surfaces.
4. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper mounting plate support rail surfaces.
5. Install the brake caliper.

Notice: Refer to Installing Hoses without Twists or Bends Notice in the Preface section.

6. Install the brake hose.
7. Loosely assemble the brake hose nut to the brake caliper.

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.

8. Loosely assemble the brake hose bracket to the brake caliper.

Tighten

• | Tighten the brake hose nut to 19 N·m (14 lb ft).

• | Tighten the brake hose bracket bolts to 32 N·m (24 lb ft).

9. Install the wheel speed sensor.
10. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper retainer and the brake caliper spring.
11. Tap the brake caliper retainer (3) and brake caliper spring (2) into place using a brass punch and a light weight hammer. The hose in the brake caliper retainer should line up with the threaded hole in the brake caliper mounting plate (4).

Important:

• | The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

• | Do not reuse the brake caliper retainer bolt.

12. Install a NEW brake caliper retainer bolt.

Tighten
Tighten the brake caliper retainer bolt (1) to 40 N·m (29 lb ft).

13. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 1052535, or equivalent. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

15. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
16. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
17. Lower the vehicle.

Caution: Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.

18. Remove the wheel blocks.

## Front Brake Caliper Replacement Dayton-Walther

### Removal Procedure

1. Apply the parking brake.
2. Block the wheels.

Important:

• | Do not completely drain the master cylinder reservoir.

• | Drain the fluid from the brake caliper bleeder valve.

• | Drained the fluid into a suitable container. Discard the fluid.

3. Remove about 2/3 of the brake fluid from the master cylinder reservoir.
4. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Remove the brake caliper retainer bolt (1).
7. Remove the brake caliper retainer (3) and brake caliper spring (2) using a brass punch.
8. Compress the pistons, using one of the following methods:

• | Use screwdrivers to pry between the outer brake caliper housing and the outer brake pad.

• | Use a C-clamp between the inner brake caliper housing and the outer brake pad.

9. While compressing the pistons, watch the reservoir for possible brake fluid overflow.
10. Remove the wheel speed sensor.
11. Disconnect the brake hose.
12. Cap or tape the brake hose fitting in order to prevent contamination.

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

13. Remove the brake caliper.

### Inspection Procedure

Caution: Avoid taking the following actions when you service wheel brake parts:

• | Do not grind brake linings.

• | Do not sand brake linings.

• | Do not clean wheel brake parts with a dry brush or with compressed air.

Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne.
1. Clean the area around the brake hose on the brake caliper. Use Brake Parts cleaner GM P/N 12345754 or the equivalent.
2. Inspect the support rail surfaces on the brake caliper.
3. Inspect the support rail surfaces on the brake caliper mounting plate.
4. Inspect the heat shields. If the heat shields are loose, replace the shields.

### Installation Procedure

1. Clean the support rail surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the support rail surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.
3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper support rail surfaces.
4. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper mounting plate support rail surfaces.
5. Install the brake caliper.

Notice: Refer to Installing Hoses without Twists or Bends Notice in the Preface section.

6. Install the brake hose.
7. Loosely assemble the brake hose nut to the brake caliper.

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.

8. Loosely assemble the brake hose bracket to the brake caliper.

Tighten

• | Tighten the brake hose nut to 19 N·m (14 lb ft).

• | Tighten the brake hose bracket bolts to 32 N·m (24 lb ft).

9. Install the wheel speed sensor.
10. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper retainer and the brake caliper spring.
11. Tap the brake caliper retainer (3) and brake caliper spring (2) into place using a brass punch and a light weight hammer. The hose in the brake caliper retainer should line up with the threaded hole in the brake caliper mounting plate (4).

Important:

• | The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

• | Do not reuse the brake caliper retainer bolt.

12. Install a NEW brake caliper retainer bolt.

Tighten
Tighten the brake caliper retainer bolt to 40 N·m (29 lb ft).

13. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 1052535, or equivalent. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

15. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
16. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

Caution: Refer to Vehicle Lifting and Jacking Notice in the Preface section.

18. Remove the wheel blocks.