Chevrolet Sonic Repair Manual: Rear Brake Caliper Replacement
- Removal Procedure
-
Warning:
Refer to Brake Dust Warning.
Warning:
Refer to Brake Fluid Irritant Warning.
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
- Remove the tire and wheel assembly. Refer to Tire and Wheel Removal
and Installation.
- Remove the parking brake cable retaining clip (1) from the parking brake
cable bracket.
- Disconnect the parking brake cable (1) from the actuator lever, remove
the cable from the bracket and position aside.
- Remove the brake hose fitting bolt (1).
Note:
Do not reuse the brake hose fitting gaskets.
- Remove and discard the brake hose fitting gaskets (2) from the brake
hose fitting (3).
- Cap the brake hose fitting to prevent brake fluid loss and contamination.
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.
- Using a backup wrench to hold the brake caliper guide pins stationary,
remove the brake caliper guide pin bolts (1).
- Remove the brake caliper.
- Installation Procedure
-
Note:
The brake caliper piston must be fully retracted into
the caliper bore before installation.
- Using a brake caliper piston spanner tool, rotate the brake caliper
piston clockwise while applying pressure to the face of the caliper piston
to compress the piston into the caliper bore.
Note:
Ensure the notches in the caliper piston are properly
aligned with the pins on the disc brake pad backing plate.
- Position the brake caliper over the brake pads and to the caliper bracket.
Caution:
Refer to Fastener Caution.
- Using a backup wrench to hold the brake caliper guide pins stationary,
install the brake caliper guide pin bolts (1) and tighten to 28 Y (21 lb ft)
.
Note:
Install new brake hose fitting gaskets.
- Assemble the brake hose fitting bolt (1) and the new brake hose fitting
gaskets (2) to the brake hose fitting (3).
- Install the brake hose assembly and tighten the brake hose fitting bolt
to 40 Y (30 lb ft)
.
- Install the parking brake cable (1) to the parking brake cable bracket
and the actuator lever.
- Install the parking brake cable retaining clip (1) from the parking
brake cable bracket.
- Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
- Install the tire and wheel assembly. Refer to Tire and Wheel Removal
and Installation.
Removal Procedure
Warning: Refer to Brake Dust Warning.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Remove the tire and wheel assembly. Refer ...
Removal Procedure
Warning: Refer to Brake Dust Warning.
Warning: Refer to Brake Fluid Irritant Warning.
Raise and support the vehicle. Refer to Lifting and Jacking the ...
Other materials:
Rear Seat Back Cushion Removal and Installation (40%)
Rear Seat Back Cushion Removal and Installation
Callout
Component Name
Preliminary Procedure
Remove the rear seat cushion. Refer to Rear Seat Cushion Removal
and Installation.
Remove the rear seat back cushion bolster. Re ...
Secondary Air Injection Pump Air Cleaner Pipe Replacement
Secondary Air Injection Pump Air Cleaner Pipe Replacement
Callout
Component Name
1
Hose Retainer (QTY:2)
Note: Squeeze the retainer on opposite sides to release.
2
Secondary A ...
Fuel Tank Filler Pipe Replacement
Removal Procedure
Remove the bracket fastener (1).
Lift and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
Remove the fuel tank filler pipe bracket fastener (1).
Disconnect the vent hose (2). Refer to
Plastic Collar ...
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