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Home >> Chevrolet >> 2004 >> Venture Base, Van Cargo Extended >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Disc Brake System) >> Repair Instructions >> Brake Caliper Replacement - Front >> Removal Procedure
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Removal Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Monte Carlo and 2004 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.
  1. Inspect the fluid level in the brake master cylinder reservoir.
  2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then 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, then remove brake fluid to the midway point before proceeding.
  3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the front tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub.
  6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
  7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor.
  8. Remove the C-clamp from the caliper.
    9. Fig 1: Compressing Piston Into Caliper Bore
    GM177027Courtesy of GENERAL MOTORS CORP.
  9. Remove the brake hose-to-caliper bolt (1) from the caliper.

    Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end.

  10. Plug the opening in the front brake hose (2) to prevent excessive brake fluid loss and contamination.
    11. Fig 2: Identifying Brake Hose & Components
    GM176035Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Note the location of the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design.
  11. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design.
  12. Remove the caliper (2) from the rotor and the caliper bracket (3).
    13. Fig 3: View Of Caliper, Brqacket And Caliper Pins
    GM793823Courtesy of GENERAL MOTORS CORP.
  13. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots. Refer to Disc Brake Hardware Replacement - Front .
  14. Inspect the caliper bolts (1) for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts (1) when installing the caliper.
    15. Fig 4: Front Caliper Bolts & Pin Bolts
    GM793921Courtesy of GENERAL MOTORS CORP.
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