GM 18003724 Caliper Kit,Front Brake

To remove the brake hose-to-caliper banjo fitting, first mark its position relative to the caliper and then remove the banjo bolt. Discard the old copper sealing washers and wrap a plastic bag around the hose end to prevent fluid loss and contamination. Next, remove the caliper mounting bolts and clean the caliper with brake system cleaner. Do not use kerosene or petroleum-based solvents. Place shop towels or a block of wood in the center of the caliper and use compressed air to force the piston out of the bore. Inspect the piston and caliper bore for any surface defects, replacing the piston if necessary. Pry out the piston seal and dust boot and discard them, as the overhaul kit will contain replacements. Clean the piston and cylinder bore with brake system cleaner, clean brake fluid, or denatured alcohol. Lubricate the new piston seal with clean brake fluid and position it in the cylinder groove using your fingers. For installation, install the new dust boot in the piston groove, dip the piston in clean brake fluid, and place it in the bore, depressing it to the bottom. Seat the boot in the caliper counterbore using a boot installation tool or blunt punch. Connect the brake hose to the caliper using new copper washers, aligning the union fitting with the marks made before disassembly. Finally, install the caliper, tighten the mounting bolts and brake hose fitting bolt to the specified torque, and bleed the front brake circuit.

To remove the brake hose-to-caliper banjo fitting, first mark its position relative to the caliper and then remove the banjo bolt. Discard the old copper sealing washers and wrap a plastic bag around the hose end to prevent fluid loss and contamination. Next, remove the caliper mounting bolts and clean the caliper with brake system cleaner. Do not use kerosene or petroleum-based solvents. Place shop towels or a block of wood in the center of the caliper and use compressed air to force the piston out of the bore. Inspect the piston and caliper bore for any surface defects, replacing the piston if necessary. Pry out the piston seal and dust boot and discard them, as the overhaul kit will contain replacements. Clean the piston and cylinder bore with brake system cleaner, clean brake fluid, or denatured alcohol. Lubricate the new piston seal with clean brake fluid and position it in the cylinder groove using your fingers. For installation, install the new dust boot in the piston groove, dip the piston in clean brake fluid, and place it in the bore, depressing it to the bottom. Seat the boot in the caliper counterbore using a boot installation tool or blunt punch. Connect the brake hose to the caliper using new copper washers, aligning the union fitting with the marks made before disassembly. Finally, install the caliper, tighten the mounting bolts and brake hose fitting bolt to the specified torque, and bleed the front brake circuit.

To remove the brake hose-to-caliper banjo fitting, first mark its position relative to the caliper and then remove the banjo bolt. Discard the old copper sealing washers and wrap a plastic bag around the hose end to prevent fluid loss and contamination. Next, remove the caliper mounting bolts and clean the caliper with brake system cleaner. Do not use kerosene or petroleum-based solvents. Place shop towels or a block of wood in the center of the caliper and use compressed air to force the piston out of the bore. Inspect the piston and caliper bore for any surface defects, replacing the piston if necessary. Pry out the piston seal and dust boot and discard them, as the overhaul kit will contain replacements. Clean the piston and cylinder bore with brake system cleaner, clean brake fluid, or denatured alcohol. Lubricate the new piston seal with clean brake fluid and position it in the cylinder groove using your fingers. For installation, install the new dust boot in the piston groove, dip the piston in clean brake fluid, and place it in the bore, depressing it to the bottom. Seat the boot in the caliper counterbore using a boot installation tool or blunt punch. Connect the brake hose to the caliper using new copper washers, aligning the union fitting with the marks made before disassembly. Finally, install the caliper, tighten the mounting bolts and brake hose fitting bolt to the specified torque, and bleed the front brake circuit.

Ensure that before you undertake this procedure you buy a brake caliper overhaul kit that applies to your car. For single piston caliper of automobile, begin by partially undoing the caliper and brake pads. Using brake fluid clean the exterior of the brake caliper gently and not to use gasoline kerosene or the like cleaning solvent thereafter place the brake caliper on a clean working bench. Place a piece of wood or a shop rag in the caliper to deaden the shifting of piston, then compress the caliper with the air and ease the piston out to prevent having the piston snapping off. Slide the dust boot out of the caliper bore, and use wooden or plastic material to remove the piston seal from slot. Twist the caliper bleeder valve and then dispose the sleeves, bushings and all rubber components. Dip the rest of the parts in brake fluid and let them sit for a few minutes, and then invert the parts in order to spill out as much brake fluid as possible. Analyse the piston for nicks, burrs or loss of plating and the caliper bore for similar conditions but only providing light surface honing with crocus cloth for mild corrosion. Anyone of the mounting bolts which has sign of corrosion or has been damaged in any way should also be rejected. On assembly it is important to apply clean brake fluid on the piston bores and the seal should then be inserted in the caliper bore groove as depicted below; Wipe off the piston and assemble a boot having the fold toward the open end and with the piston squarely placed in the caliper bore apply pressure to help the piston settle on the bottom. Place the dust boot in the caliper counter bore and Msh with the drift to properly set into place the dust boot under the caliper face and then fit the bleeder value. The installation is carried out in the reverse of the removal process using new copper gaskets at the brake hose connection as well as bleeding of the system. In the case of a dual-piston caliper, the procedure is slightly different, and while it is relatively safe, be careful, as the bulk of the material here is aluminum, and it can easily be scratched. When using compressed air to remove the pistons, if they do not come out at the same time, and remove the boot from the unloaded cylinder and reinsert the piston to seal the cylinder and use the spacer to pry out the other piston. Repeat all the above mentioned procedures for the pistons, and bore checks, and use only fingers to install the piston boots into the caliper bores.

Before beginning this procedure, purchase a brake caliper overhaul kit specific to your vehicle. For 1988 and earlier models, start by removing the caliper and placing it on a workbench, then take out the brake pads. Remove the shoe dampening spring from the caliper piston and secure the caliper in a vise, cushioning the interior. Work the piston out by moving the parking brake lever back and forth; if it resists, use a wrench to rotate the actuator screw until the piston is free. Remove the balance spring, retaining nut, lever, lever seal, and anti-friction washer. Press the actuator screw out, pry out the dust boot, and use a tool to remove the piston seal. If necessary, take out the banjo housing retaining bolt and housing. Inspect the caliper bore for damage and clean all parts not included in the repair kit with appropriate solvents. Dry the parts with compressed air, install the bleeder valve, and if applicable, the parking brake lever mounting bracket. Assemble the banjo housing with new copper washers, lubricate and install the new piston seal, boot, thrust washer, and shaft seal. Lubricate the actuator screw and install it in the piston, followed by the balance spring. Lubricate the piston and caliper bore, then insert the piston assembly. Use a piston compressor to push the piston in, lubricate the anti-friction washer and lever seal, and install the lever, tightening the retaining nut. Seat the boot in the caliper recess and install the dampening spring. For 1989 and later models, clean the caliper exterior, unhook the collar return springs, and remove the actuating collar. Separate the clamp rod and bushing, discard the bushing, and remove the boot retainers and boots. Replace the piston seal, inspect the caliper bore, and wash all reusable parts. Lubricate the piston bore and install the piston, then lightly lubricate the actuating collar and assemble the pushrod, boots, and retainers. Attach the preload spring, lubricate the clamp rod, and insert it into the actuator collar. Push a new bushing onto the clamp rod, lubricate the inner boot, and guide the components into the caliper. Install the collar return springs, lubricate the caliper guide pins, and check the guide pin boots. Install the brake pads and the caliper, then bleed the brakes. Adjust the parking brake free travel to ensure no binding occurs, measuring the clearance between the lever and caliper housing, which should be between 0.024 and 0.028 inch. If adjustments are needed, clean the adjusting screw threads, apply thread locking compound, and turn the screw to achieve the desired clearance, then re-check after having an assistant pump the brake pedal.

Before removing the brake caliper for overhaul, you should remove the cover from the brake fluid reservoir and adjust the fluid level if necessary.

Use new copper washers and align the union fitting with the marks made before disassembly.

Before removing the brake caliper for overhaul, you should remove the cover from the brake fluid reservoir and adjust the fluid level if necessary.

Begin by removing the cover from the brake fluid reservoir and siphoning off two-thirds of the fluid into a container for disposal.

Install the bleeder screw and complete the installation by reversing the removal steps, using new copper gaskets for the brake hose connection and bleeding the system of air.