GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Chevy P12 Chassis 🢒 Brakes 🢒 Disc Brakes 🢒 Brake Caliper Replacement

Removal Procedure

    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.

  1. Apply the parking brake.
  2. Block the vehicle wheels.
  3. Remove about 2/3 of the brake fluid from the master cylinder reservoir.
    4. • 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.
  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 Wheel Removal in Tires and Wheels.

    6. Object Number: 209267 Size: SH
  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. Object Number: 156331 Size: SH
  8. Use a C-clamp between the inner brake caliper housing and the outer brake pad.
  9. Fully compress the piston by tightening the clamp.

    10. Object Number: 241620 Size: SH
  10. Watch the reservoir for possible brake fluid overflow while compressing the piston. The inner brake pad may stay on the brake caliper mounting plate.

    11. Object Number: 241594 Size: SH
  11. Disconnect the brake hose (front shown).

    12. Object Number: 328548 Size: SH
  12. Cap or tape the brake hose fitting in order to prevent contamination.
  13. Remove the brake hose (2), if required (rear shown). Refer to Front Brake Hose Replacement and Rear Brake Hose Replacement .

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

  14. Remove the brake caliper (rear caliper shown).
  15. Inspect the caliper. Refer to Brake Caliper Inspection .
  16. Overhaul the caliper if damage is found. Refer to Brake Caliper Overhaul .

Installation Procedure

    Object Number: 171530 Size: SH
  1. Clean the area around the brake hose on the brake caliper. Use Brake Parts Cleaner GM  P/N 12345754 or the equivalent.
  2. Clean the caliper sliding surfaces with a wire brush. File smooth any deep nicks or gouges to remove dirt and rust.
  3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or the equivalent, to the brake caliper and brake caliper sliding surfaces.

    4. Object Number: 171534 Size: SH
  4. Install the pistons into the bottom of the caliper bores.
  5. If you cannot completely push the pistons into the bores by hand, place a small block of wood over the pistons and the dust boots. Never drive the pistons into the bores with a metal tool. Use a C-clamp around the wooden block and brake caliper housing in order to push in the pistons.

    6. Object Number: 241622 Size: SH
  6. Install the brake caliper (rear shown).

    7. Object Number: 241594 Size: SH

    Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

  7. Install the brake hose. Refer to Front Brake Hose Replacement and Rear Brake Hose Replacement .
  8. Select a shim. Refer to Brake Caliper/Mounting Plate Wear Adjustment for shim selection.

    9. Object Number: 209267 Size: SH
  9. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper retainer (3) and the brake caliper spring (2).
  10. Tap the brake caliper retainer (3) and brake caliper spring (2) into place using a brass punch and a light weight hammer. 

    11. 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 more than 4 times.

  11. Install the brake caliper retainer bolt (1).

    12. 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.

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

  12. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 1052535, or the equivalent. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  13. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
  14. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
  15. Check the fluid level in the master cylinder reservoir.
  16. Install the tires and wheels. Refer to Wheel Installation in Tires and Wheels.
  17. Lower the vehicle.

    18. 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.