GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 SL 🢒 Brakes 🢒 Disc Brakes 🢒 Front Brake Caliper Overhaul

Disassembly Procedure

    Object Number: 872243 Size: SH
  1. Using a small screw driver, remove the piston boot ring (slowly pry up one end of the boot ring) and the piston boot from the caliper.

    2. Object Number: 876578 Size: SH

    Caution: To prevent bodily injury, make sure to keep fingers or other body parts away from piston during removal.

    Notice: Pad interior of caliper body to provide a protective cushion for piston when it exits the caliper. This will protect piston from surface damage caused from piston/caliper body contact.

  2. Remove the piston from the caliper body by applying low pressure, non-lubricated, compressed air into the caliper inlet hole.

    3. Object Number: 872236 Size: SH

    Notice: To prevent damage to caliper body bore, use a small wooden or plastic (not metal) device to extract seal.

  3. Remove the piston seal from the groove in the caliper body.

    4. Object Number: 872234 Size: SH
  4. Remove the bleeder valve and the bleeder valve cap from the caliper body.
  5. Clean all the parts in clean denatured alcohol. Dry with non-lubricated, low pressure, compressed air. Make sure to blow out all passages in the caliper body and the bleeder valve.
  6. Inspect the piston for scoring, nicks, cracks, wear or corrosion. Replace the piston if any damage is found.

    7. Object Number: 872238 Size: SH
  7. Inspect the caliper body piston bore for scoring, nicks, wear, or corrosion. Crocus cloth can be used to remove light corrosion. If more extensive damage is present, replace the caliper.

    8. Important: Do not hone the caliper bore.

  8. Inspect the seal groove in the caliper bore for nicks or burrs. If present, replace caliper.

Assembly Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 872240 Size: SH
  1. Install the bleeder valve into the caliper body assembly.

    2. Tighten
    Tighten the front brake bleeder valve to 11 N·m (8 lb ft).

  2. Install the bleeder valve cap.

    3. Object Number: 872236 Size: SH

    Important: Make sure the seal is not twisted.

  3. Lubricate the new piston seal with clean brake fluid and install the seal into the caliper seal groove.

    4. Object Number: 866451 Size: SH
  4. Install the lubricated piston boot onto the piston.
  5. Lubricate the outside diameter of the piston with clean brake fluid.

    6. Important: Considerable force may be required to install the piston.

  6. Install the piston into the caliper body. Push the piston all the way to the bottom of the caliper bore.

    7. Object Number: 866452 Size: SH

    Important: 

       • Make sure the outside edge of the piston boot is smoothly seated in counterbore of the caliper body.
       • Work the boot ring into the groove near the open end of the caliper bore. Take care not to pinch the piston boot between the boot ring and the caliper body.
       • After installing the boot ring, lift the inner edge of the piston boot to release any trapped air. The boot must lie flat, below the level of the piston face.

  7. Install the boot ring.