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Home › Pontiac › 2002 › Aztek AWD › Repair and Diagnosis › External Pages › Different car › Section 1084 (Disc Brake System) › Repair Instructions › Brake Caliper Overhaul - Front › Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. 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, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.
  3. Remove the brake caliper. Refer to Brake Caliper Replacement - Front .
    4. Fig 1: Blowing Air Into Brake Caliper Hose Hole
    GM177039Courtesy of GENERAL MOTORS CORP.
    CAUTION: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.
    NOTE: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.
  4. Blow compressed air into the brake caliper (1) hose hole in order to remove the brake caliper piston. The piston will come out through the piston boot.
    5. IMPORTANT: Do not use abrasives to clean the brake caliper piston.
  5. Inspect and replace the brake caliper piston if any of the following conditions are found:
    • Scoring
    • Nicks
    • Corrosion
    • Worn or damaged chrome plating
    6. Fig 2: Inspecting Brake Caliper Bore
    GM177058Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result.
  6. Remove the piston seal (4) from the groove in the caliper bore (3). Use a small wooden or plastic tool.
  7. Inspect the caliper bore (3) and the seal grooves for the following conditions:
    • Scoring
    • Nicks
    • Corrosion
    • Wear
  8. Use a piece of crocus cloth in order to polish out light corrosion.
  9. Replace the caliper (3) if corrosion in and around the seal groove cannot be cleaned with a piece of crocus cloth.
    10. Fig 3: Caliper Mounting Bolt, Bracket, Boot & Slid Pins
    GM695066Courtesy of GENERAL MOTORS CORP.
  10. Inspect and replace any brake caliper bolt boots (4) that exhibit any of the following conditions:
    • Cuts
    • Tears
    • Deterioration
  11. Inspect the caliper bolts for corrosion or damage. If corrosion is found on the brake caliper bolt shaft, replace the brake caliper bolt (1) and the brake caliper bolt boot (4). Do not attempt to polish away the corrosion.
  12. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is damaged.
    13. Fig 4: Inspecting Brake Caliper Bore
    GM177058Courtesy of GENERAL MOTORS CORP.
  13. Remove the bleeder valve cap (1) and the bleeder valve (2) from the brake caliper housing (3).
  14. Clean all the parts with clean, denatured alcohol.
  15. Dry all the parts with filtered, non-lubricated compressed air.
  16. Use filtered, non-lubricated compressed air in order to blow out all of the passages in the caliper housing and the bleeder valve.
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