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Home >> Pontiac >> 2002 >> Aztek AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1084 (Disc Brake System) >> Repair Instructions >> Brake Caliper Replacement - Front >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
  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 in General Information.
  4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  5. Install two wheel lug nuts to retain the rotor to the hub.
    6. Fig 1: Compressing Piston Into Caliper Bore
    GM177027Courtesy of GENERAL MOTORS CORP.
  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. Fig 2: Identifying Brake Hose & Components
    GM176035Courtesy of GENERAL MOTORS CORP.
  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. Fig 3: Locating Brake Caliper Bolts
    GM695063Courtesy of GENERAL MOTORS CORP.
  13. Remove the brake caliper bolts (3).
  14. Remove the brake caliper from the brake caliper bracket.
    15. Fig 4: Caliper Mounting Bolt, Bracket, Boot & Slid Pins
    GM695066Courtesy of GENERAL MOTORS CORP.
  15. Inspect the brake caliper pin boots (4) for the following components:
  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.
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