GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Rear Brake Caliper Replacement

Removal Procedure

    Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

    Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

  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 suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

    6. Object Number: 808143 Size: SH
  6. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.

    7. Notice: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.

  7. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.

    8. Do not exceed 1 mm (0.039 in) of caliper piston travel.

  8. Remove the C-clamp from the caliper.

    9. Object Number: 1335522 Size: SH
  9. Remove the brake hose to caliper bolt from the brake caliper.
  10. Remove the brake hose from the brake caliper.
  11. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  12. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.

    13. Object Number: 1335465 Size: SH
  13. Remove the 2 brake caliper pin bolts.

    14. Object Number: 1312047 Size: SH
  14. Remove the park brake cable from the caliper.
  15. Remove the brake caliper from the brake caliper bracket.

Installation Procedure
  1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Disc Brake Hardware Replacement .

    2. Object Number: 1335465 Size: SH
  2. Install the brake caliper to the brake caliper bracket.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the 2 brake caliper pin bolts.

    4. Tighten
    Tighten the brake caliper pin bolts to 35 N·m (26 lb ft).


    Object Number: 1312047 Size: SH
  4. Install the park brake cable to the caliper.

    5. Object Number: 1335522 Size: SH
  5. Remove the caps or plugs from the brake caliper opening and the brake hose.

    6. Important: DO NOT reuse the copper brake hose gaskets.

  6. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  7. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper.

    8. Tighten
    Tighten the brake hose-to-caliper bolt to 50 N·m (37 lb ft).

  8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
  9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  10. Slowly release the brake pedal.
  11. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  13. Lower the vehicle.
  14. Apply and release the park brake lever 4 times.