Question about 2003 Pontiac Bonneville

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How do I replace the ear brakes? - 2003 Pontiac Bonneville

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  • Pontiac Master
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Bonneville, LeSabre, Park Avenue 2000-2005

Brake Caliper - Removal & Installation

CAUTION Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.
Inspect the fluid level in the brake master cylinder reservoir. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, 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, remove brake fluid to the midway point before proceeding.

  1. Raise the vehicle and suitably support.
  2. Remove the tire and wheel assembly.
  3. Pull down on the front park brake cable.
  4. Remove the front park brake cable from the park brake cable connector.
    NOTE When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in.) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.
  5. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. Compress the brake caliper piston into brake caliper bore to allow the piston enough clearance to slide the brake caliper off the brake rotor.
  6. Remove the C-clamp.
    NOTE Be sure to plug the opening in the brake caliper and brake hose to prevent fluid loss and/or contamination.
  7. Remove brake hose to caliper bolt attaching the brake hose to the brake caliper.
  8. Remove the brake hose from the brake caliper.
  9. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  10. Remove the park brake cable bracket from the brake caliper. Leave the park brake cable attached to the cable bracket.
  11. Disconnect the park brake cable from the park brake lever on the brake caliper.
  12. Remove the lower brake caliper pin bolt.
  13. Rotate the brake caliper up.
  14. Remove the brake caliper from the upper brake caliper pin bolt.
To install:
  1. If reusing the brake caliper retainers, clean the sleeves using denatured alcohol, or equivalent.
  2. Lubricate the brake caliper pin bolts with a thin coat of high temperature silicone lube.
  3. Install the brake caliper to the upper caliper pin bolt.
  4. Rotate the brake caliper down over the brake pads into the brake caliper bracket.
  5. Install the brake caliper pin bolts. Tighten the brake caliper pin bolts to 27 Nm (20 ft. lbs.).
  6. Remove the plugs in the brake hose end.
    NOTE Install NEW copper brake hose gaskets.
  7. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
  8. Install the brake hose to caliper bolt to the brake caliper. Tighten the brake hose to caliper bolt to 44 Nm (33 ft. lbs.).
  9. Connect the park brake cable to the park brake lever on the brake caliper.
  10. Install the park brake cable bracket to the brake caliper. Tighten the park brake cable bracket bolt to 43 Nm (32 ft. lbs.).
  11. Install the front park brake cable to the park brake cable connector.
  12. Bleed the brake system.
  13. With the engine OFF, gradually apply the brake pedal to approximately 2 / 3 of its travel distance.
  14. Slowly release the brake pedal.
  15. Wait 15 seconds, then repeat until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  16. Install the tire and wheel assembly.
  17. Lower the vehicle.

NOTE The Bosch 2U ABS system cannot increase brake pressure above master cylinder pressure applied by during braking. There is no need to depressurize the system prior to service.
  1. Remove brake fluid from the master cylinder reservoir until the reservoir is approximately 1 / 3 full.
  2. Remove the front wheel. Mark the position of the wheel to the wheel studs, prior to removal, for installation reference.
  3. Install 2 lug nuts to retain the rotor once the caliper is removed.
  4. Using a large C-clamp, bottom the piston in the caliper bore by positioning the C-clamp on the outboard pad and on the round portion of the brake caliper where the piston is housed.
  5. Remove the banjo bolt that fastens the brake hose to the brake caliper. Discard the gaskets.
  6. Cap the brake line to avoid excessive fluid loss or fluid contamination.
  7. Remove the rubber dust boots from the caliper mounting bolt heads (if equipped).
  8. Remove the caliper mounting bolts.
  9. Remove the park brake cable from the caliper.
  10. Remove the caliper from the vehicle.
  11. Remove the brake pads.
To install:
  1. Install the brake pads. Lubricate the slides where the caliper mounts on the steering knuckle with silicone grease.
  2. Install the caliper over the rotor.
  3. Install the caliper mounting bolts. Torque the mounting bolts to 38 ft. lbs. (51 Nm).
  4. Install the park brake cable.
  5. Install the rubber dust boots over the caliper mounting bolt heads (if equipped).

    How do I replace the ear brakes? - 542f486.jpg
    Fig. Measuring the caliper clearance
  6. Check the clearance between the brake caliper and caliper bracket stops. If the clearance is too tight, check the caliper leading and trailing edges for build up. File down as necessary.
  7. Connect the brake hose to the caliper. Install the brake hose banjo bolt, using new gaskets, and torque to 33 ft. lbs. (45 Nm).
  8. Remove the lug nuts used to secure the rotor.
  9. Install the wheel, aligning the reference marks made during removal, and torque the lug nuts to 100 ft. lbs. (140 Nm).
  10. Refill the master cylinder and bleed the brake system using the recommended procedure.
  11. Road test the vehicle and check for proper braking performance

Hope helps (remember rated this).

Posted on Jul 08, 2010

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Don't do this if your not comfortable working on cars ... someone could get hurt ...or your car could. Make sure front wheel are blocked and car is in either park or first gear.
  1. Don't set the parking break.
  2. Lift corner up to remove tire.
  3. Remove the two shoulder bolts on back of caliper .. .10mm I think.
  4. Pull caliper up and forward. Don't let it hank by the brake line.
  5. Remove pad, making sure to not lose the small clip that holds onto the ears of the pads.
  6. You need to get a special tool to screw in the piston that is on the caliper. This can be obtained for about $15 at most automotive store.
  7. Be careful to not tear the rubber piston boot when screwing piston back in ... go slow.
  8. Wipe caliper off of any dirt. Don't use compressed air. Use a small wire brush to remove any corrosion in the area where the pad ears go, if needed.
  9. Replace new pads into caliper and remount caliper onto rotor.
  10. Screw shoulder bolts back in. Don't force them as the shoulder fits into a hole in the backing plate. You should almost be able to screw them in by hand. tighten good
  11. Get in car and work parking brake about 5 times. This adjusts the pads to the rotors.
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The following procedure requires the use of a C-clamp and slip-joint lock pliers.
  1. Siphon off about 2/3 of the brake fluid from the master cylinder reservoirs.

CAUTION The insertion of thicker replacement pads will push the piston back into its bore and will cause a full master cylinder reservoir to overflow, possibly causing paint damage. In addition to siphoning off fluid, it would be wise to keep the reservoir cover on during pad replacement.

  1. Raise and support the front of the vehicle on jackstands. Remove the wheels.
When replacing the pads on just one wheel, uneven braking will result; always replace the pads on both wheels.
  1. Install a C-clamp on the caliper so that the frame side of the clamp rests against the back of the caliper and so the screw end rests against the metal part (shoe) of the outboard pad.
  2. Tighten the clamp until the caliper moves enough to bottom the piston in its bore. Remove the clamp.
  3. Remove the 2 Allen head caliper mounting bolts enough to allow the caliper to be pulled off the disc.
  4. Remove the inboard pad and loosen the outboard pad. Place the caliper where it will not strain the brake hose; it would be best to wire it out of the way.
  5. Remove the pad support spring clip from the piston.
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  8. Check the inside of the caliper for leakage and the condition of the piston dust boot.
To install:
  1. Lubricate the 2 new sleeves and 4 bushings with a silicone spray.
  2. Install the bushings in each caliper ear. Install the 2 sleeves in the 2 inboard ears.
  3. Install the pad support spring clip and the old pad into the center of the piston. You will then push this pad down to get the piston flat against the caliper. This part of the job is a hassle and requires an assistant. While the assistant holds the caliper and loosens the bleeder valve to relieve the pressure, obtain a medium pry bar and try to force the old pad inward, making the piston flush with the caliper surface. When it is flush, close the bleeder valve so that no air gets into the system.
Make sure that the wear sensor is facing toward the rear of the caliper.
  1. Place the outboard pad in the caliper with its top ears over the caliper ears and the bottom tab engaged in the caliper cutout.
  2. After both pads are installed, lift the caliper and place the bottom edge of the outboard pad on the outer edge of the disc to make sure that there is no clearance between the tab on the bottom of the shoes and the caliper abutment.
  3. Place the caliper over the disc, lining up the hole in the caliper ears with the hole in the mounting bracket. Make sure that the brake hose is not kinked.
  4. Start the caliper-to-mounting bracket bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure that the ends of the bolts pass under the retaining ears of the inboard shoe.
  5. Push the mounting bolts through to engage the holes in the outboard shoes and the outboard caliper ears and then threading them into the mounting bracket.
  6. Torque the mounting bolts to 37 ft. lbs. (50 Nm). Pump the brake pedal to seat the linings against the rotors.
  7. Using a pair of slip-joint locking pliers, place them on the notch on the caliper housing, bend the caliper upper ears until no clearance exists between the shoe and the caliper housing.
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  1. Don't set the parking break.
  2. Lift corner up to remove tire.
  3. Remove the two shoulder bolts on back of caliper .. .10mm I think.
  4. Pull caliper up and forward. Don't let it hank by the brake line.
  5. Remove pad, making sure to not lose the small clip that holds onto the ears of the pads.
  6. You need to get a special tool to screw in the piston that is on the caliper. This can be obtained for about $15 at most automotive store.
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  9. Replace new pads into caliper and remount caliper onto rotor.
  10. Screw shoulder bolts back in. Don't force them as the shoulder fits into a hole in the backing plate. You should almost be able to screw them in by hand. tighten good
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  1. Remove the cover on the master cylinder and siphon enough fluid out of the reservoirs to bring the level to 2/3 full. This step prevents spilling fluid when the piston is pushed back.
  2. Raise and support the vehicle. Remove the front wheels and tires.
  3. Push the brake piston back into its bore using a C-clamp to pull the caliper outward.
  4. Unfasten the brake hose fitting from the caliper using a flare nut wrench, cap the fitting to prevent foreign material from entering the or the hose.
  5. Remove the two bolts which hold the caliper and then lift the caliper off the disc.
  1. Remove the inboard and outboard shoe.
If the pads are to be reinstalled, mark them inside and outside.
  1. Remove the pad support spring from the piston.
  2. Remove the two sleeves from the inside ears of the caliper and the 4 rubber bushings from the grooves in the caliper ears.
  3. Remove the caliper.
  4. Check the inside of the caliper for fluid leakage; if so, the caliper should be overhauled.
To install:
  1. Lubricate the sleeves, rubber bushings, bushing grooves, and the end of the mounting bolts using silicone lubricant.
  2. Install new bushing in the caliper ears along with new sleeves. The sleeve should be replaced so that the end toward the shoe is flush with the machined surface of the ear.
  3. Install the brake pads.
  4. With the two pads in position, place the caliper over the brake disc and align the holes in the caliper with those of the mounting bracket.
  1. Fill the cavity between the bolt bushings with silicone grease. Install the mounting bracket bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure that the ends of the bolts pass under the retaining ears on the inboard pad.
For best results, always use new bushings, sleeves and bolt boots.
  1. Tighten the mounting bolts to 35 ft. lbs. (47 Nm) for R/V Series; 28 ft. lbs. (38 Nm) for 1988-92 C/K Series and 38 ft. lbs. (51 Nm) for 1993-98 C/K Series.
  2. Connect the brake hose to the caliper and tighten the fitting until the are snug.
  3. Pump the brake pedal to seat the pad against the rotor. Don't do this unless both calipers are in place. Use a pair of channel lock pliers to bend over the upper ears of the outer pad so it isn't loose.
After tightening the mounting bolts, there must be clearance between the caliper and knuckle at both the upper and lower edge. On R/V Series, the clearance must be 0.010-0.024 in. (0.26-0.60mm); on C/K Series, it must be 0.005-0.012 in. (0.13-0.30mm) for 1988-91, and 0.010-0.028 in. (0.26-0.71mm) on 1992-98 models. If not, loosen the bolts and reposition the caliper.
  1. Install the front wheel and lower the truck.
  2. Add fluid to the master cylinder reservoirs so that they are 1/4 in. (6mm) from the top.
  3. Bleed the brake system.
  4. Check the fluid level again and add fluid as necessary. Do not move the vehicle until a hard pedal is obtained.

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