GM 18043520
Caliper, Driver Side

Start the front brake caliper overhaul by taking the part out of the vehicle. Insert a thin piece of wood in front of the Piston to protect it as you push compressed air into the brake hose inlet fitting port to push out the Piston. You need to detach the Piston boot seal before removing the brake caliper bleed screw cover and screw itself. The brake caliper housing needs replacement because scoring and corrosion damage its seal groove and bore. This step checks the backing surface of the brake mount bracket for damage and wear. Replace this part when needed. Use denatured alcohol to clean all regions of the Brake Caliper Bracket and housing surfaces plus all kit excluded parts. Use filter-separated air without oil to dry and clear all openings within the brake caliper housing and bleeder valve. Insert the brake caliper bleed screw and fasten it to 12 nm (106 inch lbs.), then attach the bleed screw cap. Put new seals into place while applying brake fluid on each groove. Also avoid twisting the seals when putting them in. Put brake fluid onto both brake caliper bore and pistons before putting the boot over the Piston. Set the boot install so its folded side points at the brake caliper housing Piston bore opening. Fit the boot into the caliper bore groove before lowering the Piston down to the bottom while verifying good boot placement. Set the brake caliper next to the second Piston and conducted all previous installation steps.

Lower the vehicle, and with the engine off, gradually apply the brake pedal to about 2/3 of its travel distance, slowly release it, and repeat this process until a firm pedal is achieved.

Install the boot and piston, ensuring the boot is properly seated in both the piston groove and the brake caliper bore groove.

Raise and support the vehicle, then remove the tire and wheel assembly.

Install the brake caliper back onto the vehicle.

Inspect the caliper operation, and use a C-clamp over the caliper body to push the pistons into the caliper bores for removal.

Clean the brake hose end and install a rubber cap or plug on the exposed brake pipe fitting.

Use a large C-clamp over the top of the caliper housing against the back of the outboard pad, tightening it until the pistons are fully retracted.

Remove the disc brake pads and the disc brake pad retainers from the caliper mounting bracket, and inspect the disc brake hardware.

Use 2 large C-clamps placed over the caliper housing against the back of the outboard pad, tightening them until the pistons are fully retracted.

Bleed the hydraulic brake system, reinstall the tire and wheel assembly, lower the vehicle, and fill the master cylinder reservoir to the proper level with clean brake fluid.

Install a large C-clamp over the brake caliper body and carefully direct low-pressure compressed air into the brake caliper inlet hole.

Use compressed air directed into the brake hose inlet fitting port.

Tighten the caliper bracket mounting bolts to 200 Nm (148 ft. lbs.) for JC5/JH5 brake systems or 165 Nm (122 ft. lbs.) for JH6 systems.

Remove the brake caliper from the vehicle.

Tighten the mounting bracket bolts to 300 Nm (221 ft. lbs.) and the brake caliper mounting bolts to 108 Nm (80 ft. lbs.).

Disconnect the brake hose at the caliper by removing the inlet fitting bolt.

Bleed the hydraulic brake system, reinstall the tire and wheel assembly, lower the vehicle, and fill the master cylinder reservoir to the proper level with clean brake fluid.

45 Nm (33 ft. lbs.).

Remove the brake hose to caliper bolt and discard the 2 copper brake hose gaskets.

Take care not to place fingers in front of the piston while applying compressed air, as this could cause serious injury.

Begin by replacing all components included in the repair kits and lubricating the rubber parts with clean brake fluid for easier assembly.

Replace the bracket if necessary.

Use denatured alcohol and dry them with filtered un-lubricated compressed air.

Discard the two copper brake hose gaskets, which may be stuck to the caliper or brake hose end.

Inspect the fluid level in the brake master cylinder reservoir.

Install the boot and piston, ensuring the boot is properly seated in both the piston groove and the brake caliper bore groove.

Install the brake caliper back onto the vehicle.

Proceed to take out the piston boots and seals, followed by the caliper bleed screw and its cap.

Use a clean bench free from mineral oil materials.

Clean all residue from the brake pad guiding surfaces on the brake caliper housing and mounting bracket.

Clean the brake hose fitting and cap the exposed brake pipe fitting to prevent fluid loss and contamination before removing the brake hose to caliper bolt and discarding the two copper brake hose gaskets.