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Home >> Pontiac >> 2002 >> Aztek FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 976 (Disc Brake System) >> Repair Instructions >> Brake Caliper Replacement - Front >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  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, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  6. Compress the brake caliper pistons.
    • Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.
    • Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.
    • Remove the C-clamp from the caliper.
    7. Fig 1: Compressing Brake Caliper Pistons
    GM370154Courtesy of GENERAL MOTORS CORP.
  7. Clean all dirt and foreign material from the brake hose end.
    8. IMPORTANT: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.
  8. Remove the brake hose to caliper bolt from the brake caliper.
  9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
  10. Remove the brake hose from the caliper.
    11. Fig 2: View Of Brake Hose To Caliper Bolt
    GM367082Courtesy of GENERAL MOTORS CORP.
  11. Remove the 2 brake caliper mounting bolts.
    12. Fig 3: View Of Brake Caliper Mounting
    GM789166Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.
  12. Remove the brake caliper from the brake caliper mounting bracket.
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