GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 RELAY 🢒 Preface 🢒 Cautions and Notices 🢒 Front Brake Caliper Replacement

Tools Required

J 28662 Brake Pedal Effort Gage

Removal Procedure

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

Caution: Refer to Brake Fluid Irritant 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. Install two wheel lug nuts to retain the rotor to the hub.

    6. Object Number: 177027 Size: SH
  6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
  7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.

    8. Object Number: 176035 Size: SH
  8. Remove the brake hose bolt (1).
  9. Remove the brake hose (2) from the brake caliper.
  10. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.
  11. Plug the openings in the brake caliper and the brake hose in order to prevent brake fluid loss and contamination.
  12. Clean off any dirt or corrosion on the brake caliper near the brake hose fitting.

    13. Object Number: 695063 Size: SH
  13. Remove the brake caliper bolts (3).
  14. Remove the brake caliper from the brake caliper bracket.

    15. Object Number: 695066 Size: SH
  15. Inspect the brake caliper pin boots (4) for the following components:
    16. • Cuts
    • Tears
    • Deterioration
    • Replace the bolt boots if damage exists. Refer to Front Brake Caliper Bracket Replacement .
  16. If the caliper pin boots are damaged, inspect the caliper pins for corrosion or damage. If corrosion is found on the brake caliper pin shaft, replace the brake caliper pin and the brake caliper pin boot. Do not attempt to polish away the corrosion.

Installation Procedure

    Object Number: 344282 Size: SH
  1. Ensure that the caliper bolt boots (3) are properly installed.

    2. Object Number: 695063 Size: SH
  2. Install the caliper (1) to the caliper bracket (2).

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

  3. Install the brake caliper bolts.

    4. Tighten
    Tighten the bolts to 54 N·m (40 lb ft).

  4. Remove the plugs in the brake hose end.

    5. Object Number: 176035 Size: SH

    Important: Install NEW copper brake hose gaskets  (3).

  5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
  6. Install the brake hose bolt to the brake caliper.

    7. Tighten
    Tighten the bolt to 54 N·m (40 lb ft).

  7. Remove the nuts securing the rotor to the hub.
  8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
  9. Lower the vehicle.
  10. Fill the master cylinder to the proper level . Refer to Master Cylinder Reservoir Filling .
  11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .
  12. Using the J 28662 apply approximately 778 N·m (175 lb ft) of force to the brake pedal for 10 seconds.
  13. Inspect the brake caliper and hydraulic brake system for brake fluid leaks.