GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Front Disc Brake Hardware Replacement

Removal Procedure

    Caution: Refer to Brake Dust Caution 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 support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .
  5. Using a C-clamp installed to the center of the outer brake pad and the back of the caliper, slowly compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket.

    6. Object Number: 1212960 Size: SH

    Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  6. To loosen the brake caliper pin bolts, hold the brake caliper guide pin with a wrench.
  7. Remove the lower brake caliper pin bolt.
  8. Pivot the brake caliper upward and support with mechanics wire as shown.
  9. Remove the brake pads (2) from the disc brake caliper bracket.

    10. Object Number: 891434 Size: SH
  10. Remove the brake pad retainers (2) from the disc brake caliper bracket.

    11. Object Number: 750472 Size: SH
  11. Remove the brake caliper guide pins (2) from the brake caliper mounting bracket (4).
  12. Remove the brake caliper pin boots (3) from the brake caliper mounting bracket (4).

Installation Procedure

    Object Number: 750472 Size: SH
  1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots.
  2. Install the brake caliper pin boots (3) into the brake caliper mounting bracket (4). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket.
  3. Install the brake caliper guide pins (2) to the brake caliper mounting bracket (4).

    4. Object Number: 891434 Size: SH
  4. Ensure the brake pad hardware mating surfaces (1) are clean.
  5. Install the brake pad retainers (2) to the brake caliper bracket.
  6. Install the brake pad retainers to the disc brake caliper bracket.
  7. Install the brake pads to the brake caliper bracket.
  8. Install the brake caliper to the mounting bracket.
  9. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins.

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

  10. Install the brake caliper guide pin bolts.

    11. Tighten
    Tighten the brake caliper bolts to 35 N·m (26 lb ft).

  11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
  12. Lower the vehicle.
  13. Fill the master cylinder to the proper level . Refer to Master Cylinder Reservoir Filling .