GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1998 🢒 Sun Runner - 4WD (Canada) 🢒 Brakes 🢒 Disc Brakes 🢒 Brake Caliper Overhaul

Disassembly Procedure

    Caution: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.

  1. Remove the caliper from the vehicle. Refer to Brake Caliper Replacement in this section.

    2. Object Number: 172792 Size: SH
  2. Insert a block of hard wood or a shop cloth (2) into the caliper interior (1) to catch the piston as it is forced out of the bore with compressed air.
  3. Remove the piston from the caliper by applying compressed air to the caliper brake hose connector hole.
  4. Remove the rubber boot from the caliper groove.

    5. Object Number: 172800 Size: SH
  5. Remove the piston seal (1) from the caliper (2).
  6. Remove the bleeder valve from the caliper.
  7. Remove the caliper pin bolts, with the boots, from the caliper.
  8. Clean the following items in clean denatured alcohol:
    9. • The caliper slide bushings
    • The caliper set ring
    • The piston
    • The caliper carrier
    • The caliper housing
  9. Dry the parts with unlubricated, compressed air.
  10. Blow out all passages in the caliper housing and the bleeder valve.
  11. Inspect the piston for scoring, corrosion and any damage to the chrome plating. Replace the piston if any of these conditions are observed.
  12. Inspect the caliper bore for scoring, pitting and corrosion. Use a crocus cloth to polish out any light corrosion. If the corrosion cannot be removed, replace the caliper.

Assembly Procedure
  1. Assemble the new caliper pin bolts and boots into the caliper.

    2. 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.

  2. Install the bleeder valve on the caliper.

    3. Tighten
    Tighten the bleeder valve to 10 N·m (89 lb in).

  3. Assemble a new piston seal into the caliper bore.

    4. Object Number: 172806 Size: SH
  4. Install a new piston boot (2) onto the piston (1).
  5. Install the piston into the caliper.

    6. Object Number: 172811 Size: SH
  6. Fit the piston boot (3) onto the caliper groove.
  7. Install the caliper on the vehicle. Refer to Brake Caliper Replacement in this section.