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Home >> Chevrolet >> 2009 >> Impala Police >> Repair and Diagnosis >> External Pages >> Different car >> Section 536 (Disc Brake System) >> Repair Instructions >> Front Brake Caliper Overhaul >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2007 Saturn Sky. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing Brake Caliper Piston Using Compressed Air
    GM773687Courtesy of GENERAL MOTORS CORP.
  1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement .
    2. 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.
    NOTE: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.
  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. Fig 2: View Of Dust Boot Retaining Ring
    GM777640Courtesy of GENERAL MOTORS CORP.
  3. Remove the retaining ring that secures the dust boot to the caliper housing.
    4. Fig 3: Exploded View Of Brake Caliper
    GM1212583Courtesy of GENERAL MOTORS CORP.
  4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal.
  5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal.
  6. Remove the bleeder valve cap (6).
  7. Remove the bleeder valve (7).
    8. IMPORTANT: Do not use abrasives to clean the brake caliper piston.
  8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
  9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.
  10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air.
  11. 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.
  12. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.
  13. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist.
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