Disc Brake System Chevrolet Cobalt I

Fastener Tightening Specifications

Fastener Tightening Specifications

Disc Brake Component Specifications

Disc Brake Component Specifications

Diagnostic Starting Point - Disc Brakes

Begin the disc brake system diagnosis with Diagnostic Starting Point - Hydraulic Brakes in Hydraulic Brakes. The use of the Diagnostic Starting Point will lead to the identification of the correct procedure for diagnosing the system and where the procedure is located.

Brake Rotor Thickness Measurement

1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to «Brake Pads Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-pads-replacement-front) and/or «Brake Pads Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-pads-replacement-rear) , if equipped.
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch, measure and record the thickness of the brake rotor at 4 or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement.
4. Compare the lowest thickness measurement recorded to the following specifications: Specification - Front J41/JM4 Brake rotor minimum allowable thickness after refinishing: 22.75 mm (0.896 in) Brake rotor discard thickness: 22.0 mm (0.87 in) Specification - Front JL9 Brake rotor minimum allowable thickness after refinishing: 23.0 mm (0.906 in) Brake rotor discard thickness: 22.8 mm (0.898 in) Specification - Rear Brake rotor minimum allowable thickness after refinishing: 12.0 mm (0.472 in) Brake rotor discard thickness: 11.8 mm (0.465 in)
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present.
6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement.

Brake Rotor Thickness Variation Measurement

1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to «Brake Pads Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-pads-replacement-front) and/or «Brake Pads Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-pads-replacement-rear) , if equipped.
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch, measure and record the thickness of the brake rotor at four or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the amount of thickness variation.
5. Compare the thickness variation measurement to the following specification: Specification: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in)
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement.

Brake Rotor Surface and Wear Inspection

1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to «Brake Pads Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-pads-replacement-front) and/or «Brake Pads Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-pads-replacement-rear) , if equipped.
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Inspect the friction surfaces of the brake rotor for the following braking surface conditions: Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. Cracks and/or heat spots Excessive blueing discoloration
4. If the friction surfaces of the brake rotor exhibit one or more of the braking surface conditions listed, the rotor requires refinishing or replacement.
5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces.
6. Compare the groove scoring depth recorded to the following specification: Specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in)
7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement.

Brake Rotor Assembled Lateral Runout (LRO) Measurement

Tools Required

1. J 39544-KIT Torque-Limiting Socket Set, or equivalent. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. J 41013 Rotor Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
3. J 42450-A Wheel Hub Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
4. J 45101 Hub and Wheel Runout Gage, or equivalent. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
5. J 45101-100 Conical Brake Rotor Washers. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Lateral Runout Measurement Procedure

1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: Remove the brake rotor from the vehicle. Refer to «Brake Rotor Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-replacement-front) and/or «Brake Rotor Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-replacement-rear) , if equipped. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) . Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface of the brake rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) . Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1), and one lug nut (2) onto the upper-most wheel stud. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) . Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14.
9. If the brake rotor meets the following criteria, proceed to step 10. The rotor is within specifications and is being REUSED The rotor has NOT been refinished The rotor does NOT exhibit thickness variation exceeding the maximum allowable level
10. Mount a dial indicator, J 45101 or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
11. Measure and record the assembled LRO of the brake rotor. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. Rotate the rotor until the highest reading is displayed on the dial. Mark the location of the high spot relative to the nearest wheel stud, or studs. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specification: Specification: Brake rotor maximum allowable assembled lateral runout: 0.06 mm (0.002 in).
13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer to «Brake Rotor Refinishing»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-refinishing) . After refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
15. Measure and record the assembled LRO of the brake rotor. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. Rotate the rotor until the highest reading is displayed on the dial. Mark the location of the high spot relative to the nearest wheel stud, or studs. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specification: Specification: Brake rotor maximum allowable assembled lateral runout: 0.06 mm (0.002 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Brake Pad Inspection

1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle.
2. If replacement is necessary, always replace disc brake pads in axle sets.
3. Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads.
4. Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn excessively. The disc brake pad wear should be approximately even per axle set.
5. Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation.
6. Replace the disc brake pads when the friction surface (3) is worn to within 1 mm (0.039 in) of the mounting plates.
7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.5 mm (0.020 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads.
8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance.
9. Replace the disc brake pads if any have separated from the mounting plates.
10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance.
11. Inspect the noise insulators on the brake pad mounting plate. Replace the brake pads if the noise insulators have separated from the brake pad mounting plate.

Brake Caliper Inspection

1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper piston, or pistons, into the caliper bore, or bores: The movement of a caliper piston into a caliper bore should be smooth and even. If a caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores.

Disc Brake Mounting and Hardware Inspection - Front

1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
2. 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.
3. 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.
4. Install a large C-clamp (1), over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
5. Tighten the C-clamp (1) until the caliper piston is compressed into the caliper bore leaving a gap of approximately 10 mm (0.38 in) between the disc brake pads and the brake rotor.
6. Remove the C-clamp (1) from the caliper (2).
7. Grasp the brake caliper and attempt to move the brake caliper vertically. The brake caliper should not exhibit excessive looseness.
8. Grasp the brake caliper and move the brake caliper inboard and outboard. The brake caliper should slide smoothly with minimal force.
9. Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket (5), yet slide easily on the mounting hardware without binding.
10. Inspect the disc brake pad mounting hardware, pad retainers (7), for the following: Bent mounting tabs Excessive corrosion Looseness at the brake caliper mounting bracket Excessive wear and/or looseness at the disc brake pads Missing mounting hardware
11. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
12. Inspect the brake caliper guide pins (2) by gently pushing inward, without disengaging the slides from the boots, then pull outward, and observe for the following: Bent or damaged brake caliper bolts (1) Restricted caliper guide pin movement Corrosion Split or torn boots (4) Missing boots Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins
13. If any of the conditions listed are found, the brake caliper mounting hardware requires replacement.
14. Inspect the brake caliper mounting bracket (5) for being bent, cracked, or damaged.
15. If any of the conditions listed are found, the brake caliper mounting bracket requires replacement.

Disc Brake Mounting and Hardware Inspection - Rear

1. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
2. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
3. Remove the C-clamp from the caliper.
4. Grasp the brake caliper and attempt to move the brake caliper vertically. The brake caliper should not exhibit excessive looseness.
5. Without disconnecting the hydraulic brake flex hose, remove the caliper from the caliper bracket, and support the caliper. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) .
6. Inspect the caliper bolts to ensure that they are not bent or damaged. If the bolts are bent or damaged, the bolts require replacement.
7. Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket, yet slide easily on the mounting hardware (3) without binding.
8. Inspect the disc brake pad mounting hardware, pad retainers (3), for the following: Bent mounting tabs Excessive corrosion Looseness at the brake caliper mounting bracket Excessive wear and/or looseness at the disc brake pads Missing mounting hardware
9. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
10. Inspect the brake caliper guide pins (1, 4) by gently pushing inward, without disengaging the slides from the boots, then pull outward, and observe for the following: Restricted caliper guide pin movement Corrosion Split or torn boots (2) Missing boots Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins
11. If any of the conditions listed are found, the brake caliper mounting hardware requires replacement.
12. Inspect the brake caliper mounting bracket for being bent, cracked, or damaged.
13. If any of the conditions listed are found, the brake caliper mounting bracket requires replacement.

Brake Pads Replacement - Front

Removal Procedure

1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
2. 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.
3. 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.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outboard brake pad.
8. Tighten the C-clamp evenly until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
9. Remove the C-clamp from the caliper.
10. Remove the brake caliper lower guide pin bolt (1).
11. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire (1), or equivalent.
12. Remove the brake pads from the caliper mounting bracket.
13. Remove the brake pad retainers (1) from the caliper bracket.
14. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
15. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: Restricted caliper guide pin movement Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins Split or torn boots
16. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
17. Install a large C-clamp (1) over the body of the brake caliper (3), with the C-clamp ends against the rear of the caliper body and against an old inboard brake pad (2) or a wood block installed against the caliper piston.
18. Tighten the C-clamp (1) evenly until the caliper piston is compressed completely into the caliper bore.
19. Remove the C-clamp and the old brake pad or wood block from the caliper.

Installation Procedure

1. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
2. Install the brake pad retainers (1) to the brake caliper bracket.
3. Install the brake pads to the caliper bracket.
4. Remove the support, and rotate the brake caliper into position over the disc brake pads and to the caliper mounting bracket.
5. Install the lower brake caliper guide pin bolt (1). Tighten: Tighten the bolt to 34 N.m (25 lb ft).
6. Remove the wheel nuts retaining the brake rotor to the hub.
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
8. Lower the vehicle.
9. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
10. Slowly release the brake pedal.
11. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
12. Fill the master cylinder auxiliary reservoir to the proper level. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) in Hydraulic Brakes.
13. Burnish the pads and rotors. Refer to «Burnishing Pads and Rotors»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__burnishing-pads-and-rotors) .

Brake Pads Replacement - Rear

1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
2. 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.
3. 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.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
7. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
8. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
9. Remove the C-clamp from the caliper.
10. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2).
11. Without disconnecting the hydraulic brake flexible hose, remove the caliper from the mounting bracket and secure the caliper with heavy mechanics wire, or equivalent.
12. Remove the brake pads from the caliper mounting bracket.
13. Remove the brake pad retainers (1) from the caliper bracket.
14. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
15. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: Restricted caliper guide pin movement Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins Split or torn boots
16. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
17. Using a spanner wrench type caliper piston installer, fully retract the piston into the caliper bore.

1. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
2. Install the brake pad retainers (1) to the brake caliper bracket.
3. Install the brake pads to the caliper bracket.
4. Remove the support, and install the caliper into position over the disc brake pads and to the caliper mounting bracket.
5. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). Tighten: Tighten the bolts to 34 N.m (25 lb ft).
6. Remove the wheel nuts retaining the brake rotor to the hub.
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
8. Lower the vehicle.
9. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
10. Slowly release the brake pedal.
11. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
12. Fill the master cylinder auxiliary reservoir to the proper level. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) in Hydraulic Brakes.
13. Burnish the pads and rotors. Refer to «Burnishing Pads and Rotors»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__burnishing-pads-and-rotors) .

Burnishing Pads and Rotors

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system.

This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced.

1. Select a smooth road with little or no traffic.
2. Accelerate the vehicle to 48 km/h (30 mph). IMPORTANT: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors.

Brake Caliper Replacement - Front

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, no brake fluid needs to be removed from the reservoir before proceeding.
3. 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.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
9. Remove the C-clamp from the caliper.
10. Remove the brake hose-to-caliper bolt (1) from the brake caliper.
11. Remove the brake hose (3) from the brake caliper.
12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3).
13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
14. Remove the brake caliper guide pin bolts (1).
15. Remove the brake caliper from the caliper bracket.
16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: Restricted caliper guide pin movement Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins Split or torn boots
17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.

1. Install the brake caliper to the brake caliper bracket.
2. Install the brake caliper guide pin bolts (1). Tighten: Tighten the bolts to 34 N.m (25 lb ft).
3. Remove the caps or plugs from the brake caliper opening and the brake hose (3).
4. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3).
5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper. Tighten: Tighten the bolt to 48 N.m (35 lb ft).
6. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
7. Remove the wheel nuts retaining the brake rotor to the wheel hub.
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
9. Lower the vehicle.
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.

Brake Caliper Replacement - Rear

1. Inspect the fluid level in the brake master cylinder auxiliary reservoir.
2. 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.
3. 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.
4. Release the park brake lever boot from the floor console by applying light pressure inward on the sides of the boot retainer, and pull the boot back.
5. Release the tension from the park brake cables. With the park brake lever in the released position, using ONLY HAND TOOLS, loosen the adjusting nut (1) completely to the end of the front cable threaded rod.
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
7. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
8. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
9. Release the park brake cable end (1) from the lever on the caliper.
10. Release the retaining tabs (4) securing the park brake cable to the bracket on the caliper.
11. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
12. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
13. Remove the C-clamp from the caliper.
14. Remove the brake hose-to-caliper bolt (1) from the brake caliper.
15. Remove the brake hose (3) from the brake caliper.
16. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3).
17. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
18. While using a wrench on the flats of the caliper guide pins (1), remove the brake caliper guide pin bolts (2).
19. Remove the brake caliper from the caliper bracket.
20. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: Restricted caliper guide pin movement Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins Split or torn boots
21. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.

1. Install the brake caliper to the caliper bracket.
2. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2). Tighten: Tighten the bolts to 34 N.m (25 lb ft).
3. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs (4).
4. Secure the park brake cable end (1) to the lever on the caliper.
5. Remove the caps or plugs from the brake caliper opening and the brake hose (3).
6. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3).
7. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper. Tighten: Tighten the bolt to 48 N.m (35 lb ft).
8. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#hydraulic-brake-system) in Hydraulic Brakes.
9. Remove the wheel nuts retaining the brake rotor to the wheel hub.
10. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
11. Lower the vehicle.
12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
13. Slowly release the brake pedal.
14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
15. Adjust the park brake cable tension. Refer to «Park Brake Adjustment (Disc)»(/chevrolet/cobalt/i-2004-2010/remont/parking-brake-system/#parking-brake-system__park-brake-adjustment-disc) or «Park Brake Adjustment (Drum)»(/chevrolet/cobalt/i-2004-2010/remont/parking-brake-system/#parking-brake-system__park-brake-adjustment-drum) in Park Brake.
16. Position the park brake lever boot to the floor console and press the boot retainer into place to secure.

Brake Caliper Overhaul - Front

Note. Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.

Disassembly Procedure

1. Remove the brake caliper from the vehicle. Refer to «Brake Caliper Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-front) .
2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole.
3. Remove the retaining ring that secures the dust boot to the caliper housing.
4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal.
5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal.
6. Remove the bleeder valve cap (6).
7. Remove the bleeder valve (7).
8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
9. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.
10. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air.
11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
12. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.
13. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist.

Assembly Procedure

1. Lubricate the new piston seal (4) with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
2. Install the lubricated, new piston seal (4) into the caliper bore.
3. Apply a thin coat of Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3).
4. Install the bottom half of the caliper piston (2) into the caliper bore.
5. Install the new piston dust boot seal (1) over the caliper piston (2).
6. Compress the caliper piston (2) to the bottom of the caliper bore.
7. Fully seat the piston dust boot seal (1) into caliper counterbore.
8. Install the retaining ring that secures the dust boot to the caliper housing.
9. Install the bleeder valve to the caliper. Tighten: Tighten the brake bleeder valve to 11 N.m (97 lb in).
10. Install the bleeder valve cap.
11. Install the brake caliper to the vehicle. Refer to «Brake Caliper Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-front) .

1. Remove the rear brake caliper from vehicle. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) .
2. Drain the brake fluid from the caliper assembly.
3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore.
4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston.
5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston.
6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal.
7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal.
8. Inspect the operation of the integral park brake mechanism: Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore.
9. If the integral park brake mechanism was not operating properly, binding or seized, replace the brake caliper assembly.
10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.
11. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
12. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent.
13. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent.
14. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air.
15. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist.
16. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist.

1. Lubricate the new piston seal with Saturn P/N 21013073, or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
2. Install the lubricated, new piston seal into the caliper bore.
3. Install the new dust boot seal onto the caliper piston (2).
4. Insert the caliper piston into the caliper bore. Using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1).
5. Fully seat the piston dust boot seal in the seal counterbore.
6. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore.
7. Install the brake caliper to the vehicle. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) . Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston.

Disc Brake Hardware Replacement - Front

1. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire (2), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Brake Caliper Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-front) .
2. Remove the brake pads (1) from the brake caliper bracket.
3. Remove the disc brake pad retainers (6) from the brake caliper bracket.
4. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (3), of any debris and corrosion.
5. Inspect the disc brake pad retainers (6) for the following: Bent mounting tabs Excessive corrosion Looseness at the brake caliper mounting bracket Looseness at the disc brake pads
6. If any of the conditions listed are found, the disc brake pad retainers require replacement.
7. Remove the brake caliper guide pins (1, 4) from the brake caliper bracket.
8. Remove the caliper guide pin boots (5) from the caliper bracket.
9. Inspect the caliper guide pin bores in the caliper bracket. Carefully remove any debris or corrosion from the bores.
10. Inspect the guide pin boots (5). If the boots are damaged, they require replacement.
11. Inspect the guide pins (1, 4) and the bushing (2) on the upper guide pin. If either of the guide pin assemblies is damaged or corroded, or if the bushing is damaged, the guide pins require replacement.

1. Apply a thin, light coating of high temperature silicone brake lubricant to the inside of the brake caliper guide pin boots (5).
2. Fully install the guide pin boots (5) to the brake caliper mounting bracket.
3. Apply a light coating of high temperature silicone brake lubricant to the brake caliper guide pins (1, 4), including the bushing (2) on the upper guide pin. Apply very little lubricant to the end of the upper guide pin, ahead of the bushing (2).
4. Install the brake caliper guide pins (1, 4) to the caliper mounting bracket. Ensure that the rim of the guide pin boots is fully seated in the groove on the guide pins.
5. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (3) only.
6. If reusing the brake pad retainers, clean the brake pad mating surfaces of the brake pad retainers (6).
7. Install the brake pad retainers (6) to the brake caliper bracket.
8. Install the brake pads (1) to the brake caliper bracket.
9. Remove the support (2) and reposition the brake caliper over the brake pads and to the mounting bracket. Refer to «Brake Caliper Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-front) .

Disc Brake Hardware Replacement - Rear

1. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) .
2. Remove the brake pads from the brake caliper bracket.
3. Remove the disc brake pad retainers (1) from the brake caliper bracket.
4. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
5. Inspect the disc brake pad retainers (1) for the following: Bent mounting tabs Excessive corrosion Looseness at the brake caliper mounting bracket Looseness at the disc brake pads
6. If any of the conditions listed are found, the disc brake pad retainers require replacement.
7. Remove the brake caliper guide pins (1, 2) from the brake caliper bracket.
8. Remove the caliper guide pin boots (4) from the caliper bracket.
9. Inspect the caliper guide pin bores in the caliper bracket. Carefully remove any debris or corrosion from the bores.
10. Inspect the guide pin boots (4). If the boots are damaged, they require replacement.
11. Inspect the guide pins (1, 2) and the bushing (3) on the lower guide pin. If either of the guide pin assemblies is damaged or corroded, or if the bushing is damaged, the guide pins require replacement.

1. Apply a thin, light coating of high temperature silicone brake lubricant to the inside of the brake caliper guide pin boots (4).
2. Fully install the guide pin boots (4) to the brake caliper mounting bracket.
3. Apply a light coating of high temperature silicone brake lubricant to the brake caliper guide pins (1, 2), including the bushing (3) on the lower guide pin. Apply very little lubricant to the end of the lower guide pin, ahead of the bushing (3).
4. Install the brake caliper guide pins (1, 2) to the caliper mounting bracket. Ensure that the rim of the guide pin boots is fully seated in the groove on the guide pins.
5. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
6. If reusing the brake pad retainers, clean the brake pad mating surfaces of the brake pad retainers (1).
7. Install the brake pad retainers (1) to the brake caliper bracket.
8. Install the brake pads (1) to the brake caliper bracket.
9. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) .

Brake Caliper Bracket Replacement - Front

1. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire (2), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Brake Caliper Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-front) .
2. Remove the brake pads from the brake caliper bracket.
3. Remove the brake pad retainers (1) from the brake caliper bracket.
4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
5. Inspect the disc brake pad retainers (1) for the following: Bent mounting tabs Excessive corrosion Looseness at the brake caliper mounting bracket Looseness at the disc brake pads
6. If any of the conditions listed are found, the disc brake pad retainers require replacement.
7. Remove the brake caliper mounting bracket bolts (1).
8. Remove the brake caliper bracket from the steering knuckle.
9. Inspect the caliper bracket. If the brake caliper bracket is bent, cracked, or damaged, it requires replacement.
10. Inspect the brake caliper guide pins (1, 4) for freedom of movement, and inspect the condition of the guide pin boots (5). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: Restricted caliper guide pin movement Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins Split or torn boots
11. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.

1. Install the brake caliper mounting bracket to the steering knuckle.
2. Install the brake caliper mounting bracket bolts (1). Tighten: Tighten the bolts to 115 N.m (85 lb ft).
3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
4. Clean the brake pad mating surfaces of the brake pad retainers (1).
5. Install the brake pad retainers (1) to the brake caliper bracket.
6. Install the brake pads to the brake caliper bracket.
7. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Refer to «Brake Caliper Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-front) .

Brake Caliper Bracket Replacement - Rear

1. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire, or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) .
2. Remove the brake pads from the brake caliper bracket.
3. Remove the brake pad retainers (1) from the brake caliper bracket.
4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces of the caliper bracket (2), of any debris and corrosion.
5. Inspect the disc brake pad retainers (1) for the following: Bent mounting tabs Excessive corrosion Looseness at the brake caliper mounting bracket Looseness at the disc brake pads
6. If any of the conditions listed are found, the disc brake pad retainers require replacement.
7. Remove the brake caliper mounting bracket bolts (1).
8. Remove the brake caliper bracket from the rear axle.
9. Inspect the caliper bracket. If the brake caliper bracket is bent, cracked, or damaged, it requires replacement.
10. Inspect the brake caliper guide pins (1, 4) for freedom of movement, and inspect the condition of the guide pin boots (2). Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: Restricted caliper guide pin movement Looseness in the brake caliper mounting bracket Seized or binding caliper guide pins Split or torn boots
11. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.

1. Install the brake caliper mounting bracket to the rear axle.
2. Install the brake caliper mounting bracket bolts (1). Tighten: Tighten the bolts to 115 N.m (85 lb ft).
3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces of the caliper bracket (2) only.
4. Clean the brake pad mating surfaces of the brake pad retainers (1).
5. Install the brake pad retainers (1) to the brake caliper bracket.
6. Install the brake pads to the brake caliper bracket.
7. Remove the support and reposition the brake caliper over the brake pads and to the mounting bracket. Refer to «Brake Caliper Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-replacement-rear) .

Brake Rotor Replacement - Front

Tools Required

1. J 41013 Rotor Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. J 42450-A Wheel Hub Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.
4. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
5. Remove the C-clamp.
6. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Refer to «Brake Caliper Bracket Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-bracket-replacement-front) .
7. Matchmark the position of the brake rotor to the wheel studs.
8. Remove the brake rotor.

1. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
7. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle. Refer to «Brake Caliper Bracket Replacement - Front»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-bracket-replacement-front) .
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
9. Lower the vehicle.
10. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Refer to «Burnishing Pads and Rotors»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__burnishing-pads-and-rotors) .

Brake Rotor Replacement - Rear

Tools Required

1. J 41013 Rotor Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. J 42450-A Wheel Hub Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
3. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
4. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
5. Remove the C-clamp from the caliper.
6. Remove the brake caliper and the caliper mounting bracket as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Refer to «Brake Caliper Bracket Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-bracket-replacement-rear) .
7. Matchmark the position of the brake rotor to the wheel studs.
8. Remove the brake rotor.

1. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
7. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle. Refer to «Brake Caliper Bracket Replacement - Rear»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-bracket-replacement-rear) .
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
9. Lower the vehicle.
10. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Refer to «Burnishing Pads and Rotors»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__burnishing-pads-and-rotors) .

Brake Rotor Assembled Lateral Runout (LRO) Correction

Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired.

1. The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
2. The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction - Correction Plates»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
3. The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system) .

If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern.

Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing

Tools Required

1. J 39544-KIT Torque-Limiting Socket Set, or equivalent. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. J 45101-100 Conical Brake Rotor Washers. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Lateral Runout Correction Procedure

1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining.
3. Index the brake rotor in a different orientation to the hub/axle flange.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) . Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
8. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14.
11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Brake Rotor Assembled Lateral Runout (LRO) Correction - Correction Plates

Tools Required

1. J 39544-KIT Torque-Limiting Socket Set, or equivalent. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. J 45101-100 Conical Brake Rotor Washers. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining.
4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used.
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward.
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
8. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
11. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) . Refer to «Tire and Wheel Removal and Installation»(/chevrolet/cobalt/i-2004-2010/remont/wheel-tire-system/#tires-and-wheels) in Tires and Wheels.
12. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Tools Required

J 45101-100 Conical Brake Rotor Washers. See Special Tools .

1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining.
4. Set up the lathe, following the manufacturer's instructions.
5. Refinish the brake rotor, following the brake lathe manufacturer's instructions.
6. After each successive cut, inspect the brake rotor thickness. Refer to «Brake Rotor Thickness Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-thickness-measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish Using moderate pressure, apply the non-directional finish: If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Brake Rotor Refinishing

Tools Required

1. J 41013 Rotor Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. J 42450-A Wheel Hub Resurfacing Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .

Refinishing Procedure

1. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__special-tools) .
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris.
5. Ensure that any vibration dampening attachments are securely in place.
6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces.
7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe.
9. Following the brake lathe manufacturer's instructions, refinish the brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to «Brake Rotor Thickness Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-thickness-measurement) .
11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced.
12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish Using moderate pressure, apply the non-directional finish: If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner
13. Remove the brake rotor from the brake lathe.
14. Measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Measurement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout (LRO) Correction»(/chevrolet/cobalt/i-2004-2010/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-lro) .

System Component Description

The disc brake system consists of the following components

System Operation

Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows the output force to be equally distributed. The brake pads apply the output force to the friction surfaces on both sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both the brake pad and brake caliper hardware is essential for even distribution of braking force.

Special Tools

Special Tools Illustration Tool Number/ Description J 39544-KIT Torque Limiting Socket Set J 41013 Rotor Resurfacing Kit J 42450-A Wheel Hub Resurfacing Kit J 45101 Hub and Wheel Runout Gage J 45101-100 Conical Brake Rotor Washers

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

See also:
• Diagnostic Starting Point - Hydraulic Brakes
• Brake Dust Caution
• Tire and Wheel Removal and Installation
• Brake Fluid Irritant Caution
• Lifting and Jacking the Vehicle
• Fastener Notice
• Master Cylinder Reservoir Filling
• Hydraulic Brake System Bleeding (Manual)
• Park Brake Adjustment (Disc)
• Park Brake Adjustment (Drum)
• Brake Fluid Effects on Paint and Electrical Components Notice
• Brake Pads Replacement - Front
• Brake Pads Replacement - Rear
• Special Tools
• Brake Rotor Thickness Variation Measurement
• Brake Rotor Replacement - Front
• Brake Rotor Replacement - Rear
• Brake Rotor Refinishing
• Brake Rotor Assembled Lateral Runout (LRO) Correction
• Brake Caliper Replacement - Rear
• Burnishing Pads and Rotors
• Brake Caliper Replacement - Front
• Brake Caliper Bracket Replacement - Front
• Brake Caliper Bracket Replacement - Rear
• Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe
• Brake Rotor Thickness Measurement