Chevrolet Sonic Repair Manual: Front Brake Caliper Bracket Replacement

Removal Procedure

Warning:

Refer to Brake Dust Warning.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.




Note:

• DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.
• Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolt. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brakes are applied.
3. Hold the brake caliper guide pin stationary and remove the brake caliper guide pin bolts (1).

Caution:

Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

4. Remove the brake caliper and support with heavy mechanics wire or equivalent.



Note:

Note the location of the wear sensor for correct installation.

5. Remove the inner brake pad (1).
6. Remove the outer brake pad (2).


7. Remove the brake pad springs (1).



Note:

The upper brake caliper guide pin is equipped with a bushing and must be installed in the same location.

8. Remove the upper brake caliper guide pin (1).
9. Remove the lower brake caliper guide pin (2).
10. Remove the 2 brake caliper guide pin seals.



Note:

Do not reuse the brake caliper bracket bolts.

11. Remove and discard the brake caliper bracket bolts (1).


12. Remove the brake caliper bracket (1).

Installation Procedure

1. Install the brake caliper bracket (1).



Caution:

Refer to Fastener Caution.

2. Install 2 new brake caliper bracket bolts (1) and tighten to  100 Y (74 lb ft)

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3. Install the brake pad springs (1).


4. Install the 2 brake caliper guide pin seals.
5. Ensure the brake caliper guide pin seals are fully seated in the groove of the brake caliper bracket.

Note:

The upper brake caliper guide pin is equipped with a bushing and must be installed in the same location.

6. Install the upper brake caliper guide pin (1).
7. Install the lower brake caliper guide pin (2).
8. Ensure the brake caliper guide pin seals are fully seated in the groove of the brake caliper guide pins.



Note:

Note the location of the wear sensor for correct installation.

9. Install the inner brake pad (1).
10. Install the outer brake pad (2).
11. Position the brake caliper over the brake pads and to the caliper bracket.


12. Using a backup wrench to hold the brake caliper guide pin stationary, install the brake caliper guide pin bolts (1) and tighten to  28 Y (21 lb ft)

    .

13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.

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