GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Astro - 4WD 🢒 Suspension 🢒 Tires and Wheels 🢒 Brake Caliper Replacement

Removal Procedure

    Object Number: 127 Size: SH
  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, brake fluid does not need 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 suitably 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. Only on the A4WD, install and hand tighten a wheel lug nut in order to retain the rotor.
  7. Compress the front caliper piston, with the following procedure:
    8. 7.1. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.
    7.2. Slowly tighten the C-clamp until the piston pushes into the caliper bore enough to slide the caliper off the rotor.
    7.3. Remove the C-clamp from the caliper.

    Object Number: 176035 Size: SH
  8. Remove the brake hose-to-caliper bolt (1) from the caliper.

    9. Discard the 2 copper gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.

  9. Plug the opening in the front brake hose (2) in order to prevent excess brake fluid loss and contamination.

    10. Do not pinch off the brake hose with any tools.


    Object Number: 129 Size: SH
  10. Remove the caliper mounting bolts.
  11. Remove the caliper.
  12. Remove the brake pads. Refer to Brake Pads Replacement .

    13. Object Number: 162902 Size: SH
  13. Remove the bushings.
  14. Only on the RWD, remove the sleeves.

    15. Important: Do not attempt to polish away any corrosion. If corrosion is found, use new parts, including bushings, when installing the caliper.

  15. Inspect the caliper bolts for corrosion or damage.

Installation Procedure

    Object Number: 156329 Size: SH
  1. If reusing the brake caliper pin bolts and retainers, clean the brake caliper pin bolts and retainers using denatured alcohol, or equivalent.
  2. Dry the brake caliper pin bolts using non-lubricated, filtered air.

    3. Important: DO NOT apply lubricant to the brake pad hardware.

  3. Apply high temperature silicone brake lubricant to the brake caliper pin bolts and retainers.

    4. Object Number: 162902 Size: SH
  4. Install the bushings.
  5. Only on the RWD, install the sleeves.
  6. Install the brake pads. Refer to Brake Pads Replacement .
  7. Install the caliper assembly.

    8. Object Number: 129 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  8. Install the mounting bolts.

    9. Tighten
    Tighten the bolts to 51 N·m (38 lb ft).


    Object Number: 176035 Size: SH

    Important: Install NEW copper brake hose gaskets.

  9. Install the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
  10. Install the brake hose-to-caliper bolt to the brake caliper.

    11. Tighten
    Tighten the bolt to 44 N·m (32 lb ft).

  11. Remove the wheel lug nut securing the rotor to the hub.

    12. Object Number: 162961 Size: SH
  12. Measure the clearance between the caliper and the steering knuckle.

    13. Measure the clearance at each end of the caliper individually and then add the measurements together.

    Specification
    The total should be 0.26-0.60 mm (0.010-0.024 in).

    • If the total clearance between the caliper and the steering knuckle is less than 0.26 mm (0.010 in), file the steering knuckle equally on each side until the proper clearance is obtained.
    • If the total clearance between the caliper and the steering knuckle is more than 0.60 mm (0.024 in), inspect the brake caliper and the steering knuckle for damage and replace as needed.
  13. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  14. Lower the vehicle.
  15. Fill the master cylinder to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  16. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.