Rear Brake Caliper Overhaul With Single Rear Wheel (JH5)

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

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

Note: 

1. Remove the brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement.

Warning: 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.

2. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing.



3. Remove the piston boot.
4. Remove the piston seal.
5. Remove the brake caliper bleed screw cap.
6. Remove the brake caliper bleed screw.
7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing.



8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed.
9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket.
10. Clean all of the parts not included in the repair kit with denatured alcohol.
11. Dry all the parts with non lubricated filtered compressed air.
12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the brake caliper bleed screw and tighten to 12 N·m (106 lb in).
2. Install the brake caliper bleed screw cap.
3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid.
4. Install the new seal into the brake caliper bore seal groove.
5. Ensure that the seal is not twisted.
6. Lubricate the brake caliper bore and the piston with brake fluid.
7. Install the boot and piston.

7.1.	Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening.

7.2.	Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore.

7.3.	Push down the piston to the bottom of the brake caliper bore.

7.4.	Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore.

8. Install the brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement.

Rear Brake Caliper Overhaul With Single Rear Wheel (JH6, JH7)

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

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

Note: 

1. Remove the brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement.

Warning: 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.

2. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing.
3. Remove the 2 pistons.



4. Remove the 2 piston boots.
5. Remove the 2 piston seals.
6. Remove the brake caliper bleed screw cap.
7. Remove the brake caliper bleed screw.
8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing.



9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed.
10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket.
11. Clean all the parts not included in the repair kit with denatured alcohol.
12. Dry all the parts with non lubricated filtered compressed air.
13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the brake caliper bleed screw and tighten to 12 N·m (106 lb in).
2. Install the brake caliper bleed screw cap.
3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid.
4. Install new the seal into the brake caliper bore seal groove.
5. Ensure that the seal is not twisted.
6. Lubricate the brake caliper bore and the piston with brake fluid.
7. Install the boot and the piston.

7.1.	Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening.

7.2.	Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore.

7.3.	Push down the piston to the bottom of the brake caliper bore.

7.4.	Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore.

7.5.	Repeat steps 5 and 6 for the remaining piston.

8. Install the brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement.

Rear Brake Caliper Overhaul With Dual Rear Wheel

Special Tools

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

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

Note: Replace all the components included in the repair kits used to overhaul the brake caliper.

1. Remove the brake caliper. Refer to Rear Brake Caliper Replacement.
2. Place a wood block between the brake caliper pistons and the brake caliper housing bridge.

Warning: 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.




3. Place a clean shop towel between the brake caliper pistons and the block of wood.
4. Apply compressed air through the brake hose fitting inlet port and remove the brake caliper pistons (1).
5. Remove the brake caliper bleeder screw.



6. Using a blunt wooden or plastic tool, remove the brake caliper piston dust seals (1).



7. Using a blunt wooden or plastic tool, remove the brake caliper piston seals (1).
8. Inspect the brake caliper bores for corrosion, grooves, and scoring.

•	Inspect the caliper piston bores

•	Inspect the caliper piston seal grooves

If excessive corrosion, grooving, or scoring is found, replace the brake caliper.

9. Clean the brake caliper housing and any parts to be reused with denatured alcohol.
10. Dry all components with dry, filtered, non-lubricated compressed air.

1. Apply a light coating of GM approved brake fluid from a clean, sealed brake fluid container to the brake caliper components:

•	Brake caliper piston bores

•	Brake caliper pistons

•	Brake caliper piston seals




2. Install the brake caliper piston seals (1) to the brake caliper piston bores.

Ensure the brake caliper piston seals are fully seated in the groove of the caliper piston bores and are not distorted.




3. Using the J-45515 Piston Seal Installer with the J-8092 Driver Handle , install the brake caliper piston dust seals (1).



4. Install the brake caliper pistons (1) into the brake caliper housing.

Use firm, downward hand pressure to press the brake caliper pistons squarely into the caliper bores.

5. Seat the edge of the brake caliper dust seals in the groove in the brake caliper piston.
6. If necessary, carefully lift the edge of the brake caliper dust seals at the brake caliper piston to release any trapped air.
7. Install the brake caliper. Refer to Rear Brake Caliper Replacement.