Front Brake Caliper Overhaul Procedure

(All Above Listed Vehicles)





Caution:
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.

Notice:
Use clean cloths to pad the interior of the caliper housing during piston removal. Use just enough air to ease the piston out of the bores. If the pistons are blown out, even with the padding provided it may be damaged.

1. Remove the front brake caliper from the vehicle.

2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole.





3. Using a small wooden or plastic tool, remove the caliper piston seal (2) from the seal counterbore in the caliper (1) and discard the boot seal.

4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal.

5. Remove the bleeder valve (5) and cap (6) from the caliper (1).

Important:
Do not use abrasives to clean the brake caliper piston.

6. Clean the brake caliper piston bore and seal counterbore and the caliper piston with denatured alcohol, or equivalent.

7. Dry the caliper piston bore and counterbore and the piston with non-lubricated, filtered air.

8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust and/or excessive corrosion.

9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.

10. If cracks, scoring, pitting, excessive rust and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.

11. Inspect the caliper piston for cracks, scoring and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist.

12. Lubricate the new piston seal with Delco Supreme 11(R), P/N 12377967 (in Canada use P/N 992668), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.

13. Install the lubricated new piston seal into the caliper bore.

14. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore.

15. Install the new piston dust boot seal over the piston.





16. Use J-35777 to fully seat the caliper piston seal into the counterbore.

17. Install the bleeder valve and cap to the caliper and tighten the valve securely.

18. Install the front brake caliper to the vehicle.