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Disassembly Procedure

WARNING: This page is about a different car, the 2008 Isuzu i-370, 2008 Isuzu i-290, 2008 GMC Canyon, and 2008 Chevrolet Colorado. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Applying Air To Brake Caliper
    GM1363959Courtesy of GENERAL MOTORS CORP.
  1. Drain all the brake fluid from the caliper.
    2. CAUTION: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.
    IMPORTANT: In the following service procedure, the caliper piston may become damaged when it is removed from the brake caliper assembly. DO NOT reuse the piston if it becomes damaged. Discard the piston and replace with new.
  2. Install the brake caliper in a suitable holding device.
  3. Place a piece of wood in the brake caliper in front of the pistons.
  4. Cover the brake caliper with a shop towel.
  5. Using compressed filtered, non-lubricated air, apply the air to the brake caliper hose inlet port to remove the pistons from the brake caliper.
    6. Fig 2: Clamping Brake Caliper Using Block Of Wood
    GM800797Courtesy of GENERAL MOTORS CORP.
  6. If one of the pistons fails to be removed from the brake caliper, perform the following steps.
    1. Reposition the piston that has been removed back in the brake caliper.
    2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston it is half way in the brake caliper. It does not have to be fully seated.
    3. Position a second block of wood in front of the piston that remains in the brake caliper.
    4. Cover the brake caliper with a shop towel.
    5. Using compress filtered, non lubricated air, apply the air to the brake caliper hose inlet port to remove the pistons from the brake caliper.
    7. Fig 3: Exploded View Of Brake Caliper
    GM1339829Courtesy of GENERAL MOTORS CORP.
  7. Remove the pistons (3) from the caliper bores.
  8. Remove the piston seals (2) from the caliper bores. Do not use a metal tool.
  9. Remove the bleeder valve cap (5).
  10. Remove the bleeder valve (6) from the caliper housing (1).
  11. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using non-lubricated, filtered compressed air.
    12. Fig 4: Removing Caliper Boots
    GM1363962Courtesy of GENERAL MOTORS CORP.
  12. Remove the boots from the caliper bores. Do not damage the caliper bores.
  13. Replace the pistons or the caliper if any of the following conditions exist:
    • Scoring in the caliper bores
    • Corrosion in the caliper bores
    • Pitting in the caliper bores
    • Damage to the pistons (phenolic)
  14. Clean the brake caliper assembly with denatured alcohol.
  15. Dry with filtered, non-lubricated compressed air.
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