GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 L300/LW300 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Front Brake Caliper Replacement

Removal Procedure

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

    Caution: Refer to Brake Dust Caution in the Preface section.

    Caution: Refer to Vehicle Lifting Caution in the Preface section.


    Object Number: 891667 Size: SH
  1. Raise the vehicle on the hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the wheel and the tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  3. Remove the brake hose from the caliper. Plug the openings in the caliper and the hose to avoid fluid loss and contamination.

    4. Object Number: 891759 Size: SH
  4. Remove the retaining spring from the caliper.

    5. Object Number: 891949 Size: SH
  5. Remove the caliper-to-bracket guide pins.
  6. Remove the caliper from the support bracket.

    7. Object Number: 891957 Size: SH
  7. Remove the pads from the caliper and inspect:
    8. • The guide pin sleeves and covers for damage--If damaged, replace.
    • The piston boot for deterioration--If damaged overhaul the caliper.

       Important: Do not attempt to clean away the corrosion.

    • The guide pin for damage or corrosion--Replace if damaged or corroded.

Installation Procedure

    Object Number: 891957 Size: SH
  1. Make sure the caliper piston is bottomed fully in its caliper bore.
  2. Lubricate the pin sleeve with silicone grease, and install into the caliper.
  3. Lubricate the straight section, not the threads, of the guide pins with silicone grease.

    4. Object Number: 891954 Size: SH

    Important: Linings are identified for left or right use. Install the linings so the arrow is pointing downward, with the forward rotation of the wheel.

    Important: Remove all the rust and corrosion from the caliper brackets when installing the brake pads. If installing used brake pads, remove all the rust and corrosion from the ends of the brake pads and from the notch. Make sure the brake pads move freely in the caliper bracket when the brakes are assembled.

  4. Install the inner and the outer brake pads into the caliper.

    5. Object Number: 891949 Size: SH
  5. Install the caliper body onto the caliper support.

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

  6. Install the guide pins and tighten.

    7. Tighten
    Tighten the caliper-to-bracket guide pins to 30 N·m (22 lb ft).

  7. Install the guide pin bushing caps.

    8. Object Number: 891759 Size: SH
  8. Install the caliper retaining spring.

    9. Notice: Be sure that front brake hose is routed properly. Be careful not to install front brake hose with a twist. Incorrect front brake hose installation could result in brake failure.

  9. Connect the brake hose to the caliper using new washers.

    10. Tighten
    Tighten the brake hose-to-caliper with a new washer to 40 N·m (30 lb ft).

  10. Bleed the brakes. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  12. Lower the vehicle from the hoist.