Front Brake Caliper Overhaul (J61)

Single Use Fasteners and Components Front Brake Caliper Piston Boot [4x] Front Brake Caliper Piston Seal [4x] Front Brake Hose Washer [2x]

Warning

The battery must be disconnected to prevent the brake master cylinder from pressurizing the hydraulic system during its automated self diagnostic tests that can possibly occur when a door is opened or the key transmitter is activated. Failure to follow this precaution may cause personal injury.

Warning

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.

Warning

Brake Dust Warning

Warning

Brake Fluid Irritant Warning

Caution

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.

Caution

This brake caliper is coated with a specialized paint. Use care when handling and servicing to ensure the paint does not get chipped or scratched. Clean any brake fluid from painted surfaces with denatured alcohol, or equivalent, as soon as possible. Removal Procedure Remove the front brake caliper. Front Brake Caliper Replacement Disassembly Procedure

Note

It will be necessary to fabricate one or more blocks of wood to the following dimensions to be used during this procedure: Must fabricate 1 block: 19 mm (¾ in) X 72 mm (3 in) X 72 mm (3 in) Optional to fabricate 1 block, rather than using an old brake pad: 19 mm (¾ in) X 72 mm (3 in) X 133 mm (5.25 in) Optional to fabricate 1 block to cushion piston removal: 19 mm (¾ in) X 72 mm (3 in) X 133 mm (5.25 in)

1. Place the caliper in a vise using plastic vise caps or suitable material to protect the caliper mounting bosses from the vise jaws.

Note

Protect the caliper painted surfaces while using the C-Clamp.

2. Place a discarded brake pad or the fabricated 133 mm (5.25 in) long block of wood over 2 adjoining caliper piston bores and secure in place with a non-marring C-clamp.
3. Place the fabricated 72 mm (3 in) long block of wood over one of the opposing caliper piston bores and secure it in place with a non-marring C-clamp.
4. Use clean cloths or the other fabricated 133 mm (5.25 in) long block of wood to cushion the interior of caliper housing during removal of the caliper piston.

Front Brake Caliper Overhaul (J61) — figure 1

5. Carefully remove the brake caliper piston (1) by directing low pressure compressed air into the brake hose fitting inlet.
6. Move the fabricated 72 mm (3 in) long block of wood over the emptied caliper piston bore and secure it in place with a non-marring C-clamp.
7. Move the clean cloths or the other fabricated 133 mm (5.25 in) long block of wood to cushion the interior of caliper housing during the removal of the piston.

Front Brake Caliper Overhaul (J61) — figure 2

8. Carefully remove the brake caliper piston by directing low pressure compressed air into the brake hose fitting inlet.

Front Brake Caliper Overhaul (J61) — figure 3

9. Using care to not scratch or mar the painted surfaces or piston bore, remove the caliper piston dust boot seals (1) using a flat-bladed tool. DISCARD the dust boot seals.

Front Brake Caliper Overhaul (J61) — figure 4

10. Using wooden or plastic tool, remove the caliper piston seals (1) from the brake caliper bores. DISCARD the caliper piston seals.
11. Repeat steps 1 through 10 for the opposite side of the caliper.
12. Remove the caliper from the vise and clean the entire caliper with denatured alcohol, or equivalent.
13. Dry the caliper piston bores with non-lubricated, filtered compressed air.
14. Inspect the caliper piston bores and piston seal counter-bores for scratches, cracks, pitting, and/or corrosion.

Note

Do NOT clean the caliper piston bores by honing or cleaning with abrasives.

15. If the caliper piston bores are scratched, cracked, or pitted, or if corrosion cannot be cleaned with denatured alcohol, replace the caliper assembly.

Front Brake Caliper Overhaul (J61) — figure 5

16. Front Brake Caliper Bleeder Valve Cap (2) » Remove

17. Front Brake Caliper Bleeder Valve (1) » Remove Assembly Procedure

18. Front Brake Caliper Bleeder Valve (2) » Install and hand tighten

19. Front Brake Caliper Bleeder Valve Cap (2) » Install

20. Lubricate the NEW caliper piston seals (1) with GM approved brake fluid from a clean, sealed brake fluid container. Adhesives, Fluids, Lubricants, and Sealers

21. Install the lubricated, NEW caliper piston seals into the brake caliper piston bore seal grooves. Ensure the seals are not twisted.

22. Install the NEW caliper piston dust boot seals (1) over adjoining brake caliper piston bores.

23. Place a clean discarded brake pad or the fabricated 133 mm (5.25 in) long block of wood over the 2 adjoining caliper piston bores and apply light pressure with non-marring C-clamp. This will ensure the dust boot seals are fully seated into the caliper.

24. Lightly lubricate the brake caliper piston bores and outer surface of the brake caliper pistons with GM approved brake fluid from a clean, sealed brake fluid container. Adhesives, Fluids, Lubricants, and Sealers

25. Install the caliper piston (1) into the caliper bores. Press the caliper piston all the way in by hand.

26. Repeat steps 5 - 7 for the other pistons. Installation Procedure Install the front brake caliper. Front Brake Caliper Replacement