Disc Brake System Chevrolet Impala IX

Fastener Tightening Specifications

Disc Brake Component Specifications

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 «Front Disc Brake Pads Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) and/or «Rear Disc Brake Pads Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
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. Compare the lowest thickness measurement recorded to the specifications listed in «Disc Brake Component Specifications»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__disc-brake-component-specifications) .
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

Note. Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation.

1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to «Front Disc Brake Pads Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) and/or «Rear Disc Brake Pads Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-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. 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 «Front Disc Brake Pads Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) and/or «Rear Disc Brake Pads Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
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, 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.

Special Tools

1. CH-41013: Rotor Resurfacing Kit
2. CH-42450-A: Wheel Hub Resurfacing Kit
3. CH-45101: Hub and Wheel Runout Gauge
4. CH-45101-100: Conical Brake Rotor Washers

For equivalent regional tools, refer to Special Tools .

Note. Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement .

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 «Front Brake Rotor Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) and/or «Rear Brake Rotor Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) . Using the CH-42450-A: wheel hub resurfacing kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. Using the CH-41013: rotor resurfacing kit , thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 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 th CH-45101-100: conical brake rotor washers (1), and one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining CH-45101-100: conical brake rotor washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern.
7. Tighten the lug nuts in a star-pattern to specification. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/wheel-tire-system/#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, CH-45101: hub and wheel runout gauge, 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.
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: Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Rear brake rotor maximum allowable assembled lateral runout: 0.05 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/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) . After refinishing the rotor, proceed to step 14 .
14. Mount a dial indicator, CH-45101: hub and wheel runout gauge, 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.
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: Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) Rear brake rotor maximum allowable assembled lateral runout: 0.05 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 Correction»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
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 CH-45101-100: conical brake rotor washers and the lug nuts.

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 prematurely. 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 0.76 mm (0.030 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 0.13 mm (0.005 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.

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 pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the 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.

Front Disc Brake Mounting and Hardware Inspection

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.
3. 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.
4. Raise and support the vehicle. Refer «Lifting and Jacking the Vehicle»(/chevrolet/impala/ix-2006-2016/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/wheel-tire-system/#tires-and-wheels) .
6. Grasp the brake caliper housing and try to move the brake caliper housing up/down and forward/reverse in relation to the brake caliper mounting bracket. If excessive looseness is observed the brake caliper bracket bushings and/or the brake caliper mounting bolts may need to be replaced.
7. Compress the front caliper pistons. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. Remove the C-clamp from the caliper.
8. With the pistons compressed into the caliper bores, grasp the brake caliper housing and slide it back and forth on the brake caliper mounting bolts. Check for smooth operation. If the brake caliper housing slide force is high or the brake caliper housing does not slide smoothly, inspect the brake caliper mounting bolts and/or the brake caliper mounting bracket bushings for wear or damage. If wear or damage conditions are found, replacement of the brake caliper mounting bolts and/or the brake caliper mounting bracket bushings is necessary.
9. Remove the brake caliper mounting bolts from the brake caliper mounting bracket and support the brake caliper using heavy mechanics wire. Do Not remove the hydraulic brake hose from the caliper. Refer to «Front Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
10. Remove the disc brake pads from the brake caliper mounting bracket.
11. Inspect the disc brake pad mounting hardware for the following: Missing mounting hardware Excessive corrosion Bent mounting tabs Looseness at the brake caliper mounting bracket Looseness at the disc brake pads Excessive contaminants in the brake caliper mounting bracket surface and threads.
12. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
13. Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket, yet slide easily on the mounting hardware without binding.
14. Inspect the caliper bolts (1) for the following: Binding Seizing Looseness in the brake caliper mounting bracket (3) Bent or damaged brake caliper mounting bolts Cracked or torn boots (4) Missing boots Bent or damaged brake caliper mounting bracket (3)
15. If any of the conditions listed are found then the brake caliper mounting hardware requires replacement.
16. Install the disc brake pads to the brake caliper mounting bracket.
17. Install the disc brake caliper to the brake caliper mounting bracket. Refer to «Front Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .

Rear Disc Brake Mounting and Hardware Inspection

1. Inspect the disc brake pad mounting hardware for the following: Missing mounting hardware Excessive corrosion Bent mounting tabs Looseness at the caliper mounting bracket Looseness at the disc brake pads
2. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
3. Ensure the disc brake pads are held firmly in place on the caliper mounting bracket, yet slide easily on the mounting hardware without binding.
4. Inspect the caliper bolts (1) for the following: Binding Seizing Looseness in the caliper mounting bracket (3) Bent or damaged caliper bolts Cracked or torn boots (4) Missing boots Bent or damaged caliper mounting bracket (3)
5. If any of the conditions listed are found, the caliper mounting hardware requires replacement.

Scheme 7

Removal Procedure

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»(/chevrolet/impala/ix-2006-2016/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
4. Remove the rear tire and the wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/wheel-tire-system/#tires-and-wheels) .
5. Install a hand tightened lug nut to retain the rotor to the hub.
6. Compress the caliper piston enough for clearance. Use a C-clamp (3).
7. Remove the upper caliper bolt (2).
8. Pivot the caliper down in order to access the pads. It is not necessary to remove the caliper.
9. Remove the brake pads (2) from the caliper bracket.
10. Remove the 2 pad clips (1) from the caliper bracket.
11. Inspect the caliper mounting hardware for the following conditions: Cuts Tears Deterioration Replace any hardware if damage exists. Refer to «Rear Disc Brake Mounting and Hardware Inspection»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) .
12. Inspect the caliper dust boot for the following conditions: Cuts Tears Deterioration Replace the caliper dust boot if damage exists. Refer to «Brake Caliper Inspection»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-inspection) .
13. Inspect the caliper bolts for corrosion or damage. If corrosion exists, use new caliper bolts when installing the caliper.

Installation Procedure

1. Bottom the piston into the caliper bore. Use a C-clamp before installing new brake pads in order to compress the piston. Use an old brake pad or wooden block across the face of the piston to avoid damage to the piston or the caliper boot.
2. Install the 2 retainers (1) to the caliper bracket. NOTE: The wear sensor is on the outside pad. The sensor is positioned at the trailing or downward edge of the pad during forward wheel rotation.
3. Install the pads (2) to the caliper bracket.
4. Swing the caliper (3) upward in position around the pads.
5. Lubricate the bolt and the bolt boot. Use silicone grease.
6. Install the upper caliper bolt (2). Tighten: Tighten the caliper bolt to 44 N.m (32 lb ft).
7. Remove the wheel lug nut retaining the rotor to the hub.
8. Install the rear tire and the wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/wheel-tire-system/#tires-and-wheels) . Align the previous marks on the wheel, hub and bearing.
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 repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
13. Fill the brake master cylinder reservoir to the proper level. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
14. Burnish the pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

Brake Pad and Rotor Burnishing

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). NOTE: 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.

Scheme 8

Scheme 9

1. J-8092: Driver Handle 3/4 inch-10
2. J-45863: Dust Seal Installer

Disassembly Procedure

1. Drain all the brake fluid from the caliper.
2. Install the brake caliper in a suitable holding devise.
3. Insert a piece of wood in the brake caliper.
4. Cover the brake caliper with a shop towel.
5. Using compressed filtered, non-lubricated air, apply the air to the remove the pistons from the brake caliper.
6. If one of the pistons fails to be removed from the brake caliper, perform the following steps. Reposition the piston that has been removed back in the brake caliper. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston it is half way in the brake caliper. It does not have to be fully seated. Position a second block of wood in front of the piston that remains in the brake caliper. Cover the brake caliper with a shop towel. Using compress filtered, non lubricated air, apply the air to the remove the pistons from the brake caliper.
7. Remove the pistons (3) from the caliper bores.
8. Remove the piston seals (2) from the caliper bores. Do not use a metal tool.
9. Remove the bleeder valve cap (5).
10. Remove the bleeder valve (6) from the caliper housing (1).
11. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use dry and filtered compressed air.
12. Remove the boots from the caliper bores. Do not scratch the caliper bores.
13. Replace the pistons or the caliper if any of the following conditions exist: Scoring in the caliper bores Corrosion in the caliper bores Pitting in the caliper bores Damage to the pistons (phenolic)
14. Clean the brake caliper assembly with denatured alcohol.
15. Dry with filtered, lubricated compressed air.

Assembly Procedure

1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore.
2. Install the piston seal in the brake caliper.
3. Install the dust seal on the piston.
4. Install the piston in the brake caliper.
5. Position a piece of wood across the piston to be installed.
6. Applying equal pressure by hand while pushing down, install the piston in the bore.
7. Remove the piece of wood.
8. Using the J-8092: Driver Handle 3/4 inch-10 (1) and the J-45863: Dust Seal Installer (2), install the piston dust seal in the brake caliper.
9. Install the bleeder valve in the brake caliper housing and tighten to 13 N.m (115 lb in).
10. Install bleeder valve cap.

1. Remove the rear brake caliper from the vehicle. Refer to «Rear Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
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. 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. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.
7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air.
8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
9. 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.
10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.
11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist.

1. Lubricate the new piston seal (4) with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), 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 Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) 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 and cap to the caliper and tighten the valve securely.
10. Install the rear brake caliper to the vehicle. Refer to «Rear Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .

1. Remove the brake caliper from the mounting bracket and support the brake caliper (2) with heavy mechanic's wire (1), or equivalent. Discard the old caliper pin bolts, new bolts are supplied in the hardware kit. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. Refer to «Front Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
2. Remove the brake pads (2) from the brake caliper bracket.
3. Remove the brake pad retainers (1) from the brake caliper bracket.
4. Remove the brake caliper bracket. Refer to «Front Brake Caliper Bracket Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
5. Mount the brake caliper bracket (1) in a vise.
6. Using a flat bladed tool or punch carefully remove the caliper pin boots (2) from brake caliper bracket (1).
7. Thoroughly clean the caliper bracket bores of all lubricant.

1. Lubricate the bores (3), the inside part of the bolt boot (2) and the caliper pin bolts (4) with GM P/N 18047666, or equivalent.
2. Press the new caliper pin bolt boots into the caliper pin bores.
3. Install the brake caliper bracket. Refer to «Front Brake Caliper Bracket Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
4. Install the brake pad retainers (1) to the caliper bracket.
5. Install the brake pads (2) to the caliper bracket.
6. Remove the heavy mechanics wire (1) and install the brake caliper. Refer to «Front Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .

1. Remove the brake caliper from the mounting bracket and support the brake caliper (2) with heavy mechanic's wire (1), or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. Refer to «Rear Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
2. Remove the brake pads (2) from the brake caliper bracket (1).
3. Remove the brake pad retainers (1) from the brake caliper bracket (3).
4. Remove the brake caliper bracket (3). Refer to «Rear Brake Caliper Bracket Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
5. Mount the brake caliper bracket (3) in a vise.

1. Clean all parts in clean, denatured alcohol.
2. Dry with low pressure, non-lubricated, filtered air.
3. Inspect the brake caliper bracket for cracks. If cracked, replace bracket.
4. Lubricate the brake caliper pin bolt sleeves with high temperature silicone lubricant.
5. Install the brake caliper bracket. Refer to «Rear Brake Caliper Bracket Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
6. Install the brake pad retainers (1) to the bracket caliper bracket (3).
7. Install the brake pads (2) to the bracket caliper bracket (3).
8. Install the brake caliper to the brake caliper bracket. Refer to «Rear Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .

Scheme 10

1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. Refer to «Rear Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
2. Remove the rear brake pads.
3. Remove the caliper bracket bolts (2).
4. Remove the caliper bracket (1).

1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle.
2. Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the brake caliper bracket bolts (2).
3. Install the caliper bracket (1) with the bracket bolts (2). Tighten: Tighten the caliper bracket bolts to 120 N.m (88 lb ft).
4. Install the rear brake pads.
5. Install the caliper. Refer to «Rear Brake Caliper Replacement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .

Scheme 11

Scheme 12

Brake Rotor Assembled Lateral Runout Correction

Note. Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement . Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement .

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 Correction - Indexing»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
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 Correction - Correction Plates»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
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 Correction - On Vehicle Lathe»(/chevrolet/impala/ix-2006-2016/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.

CH-45101-100: Conical Brake Rotor Washers

For equivalent regional tools, refer to Special Tools .

1. Remove the CH-45101-100: Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure.
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 CH-45101-100: Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining CH-45101-100: Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern.
7. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/wheel-tire-system/#tires-and-wheels) .
8. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
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 Correction»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
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 CH-45101-100: Conical Brake Rotor Washers and the lug nuts.

CH-45101-100: Conical Brake Rotor Washers

For equivalent regional tools, refer to 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 CH-45101-100: Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure.
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 CH-45101-100: Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining CH-45101-100: Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern.
11. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/wheel-tire-system/#tires-and-wheels) .
12. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
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 CH-45101-100: Conical Brake Rotor Washers and the lug nuts.

CH-45101-100: Conical Brake Rotor Washers

For equivalent regional tools, refer to 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 CH-45101-100: Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure.
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/impala/ix-2006-2016/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.
9. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
10. Remove the lathe from the vehicle.
11. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
12. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
13. 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 CH-45101-100: Conical Brake Rotor Washers and the lug nuts.

1. CH-41013: Rotor Resurfacing Kit
2. CH-42450-A: Wheel Hub Resurfacing Kit

For equivalent regional tools, refer to Special Tools .

Note. The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: Brake system noise - squeal, growl, groan Uneven and/or premature disc brake pad wear Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface Scoring of the disc brake rotor friction surface less than the maximum allowable specification Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement . Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: Thickness variation in excess of the maximum allowable specification Excessive corrosion/rust and/or pitting Cracks and/or heat spots Excessive blueing discoloration Scoring of the disc brake rotor surface in excess of the maximum allowable specification Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification.

Note. If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions.

1. Using the CH-42450-A: Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
2. Using the CH-41013: Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
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/impala/ix-2006-2016/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 and wipe each friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles.
13. Remove the brake rotor from the brake lathe.
14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system) .
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/impala/ix-2006-2016/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .

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.

Illustration Tool Number/ Description J-39544-KIT Complete Torque Socket Set - 10 Pieces J-41013 Rotor Resurfacing Kit J-42450-A Wheel Hub Resurfacing Kit J-45101 Hub and Wheel Runout Gauge J-45101-100 Conical Brake Rotor Washers J-45863 Dust Seal Installer GMT355 J-8092 Drive Handle

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

See also:
• Brake Dust Warning
• Tire and Wheel Removal and Installation
• Lifting and Jacking the Vehicle
• Brake Fluid Irritant Warning
• Fastener Caution
• Master Cylinder Reservoir Filling
• Hydraulic Brake System Bleeding (Manual)
• Brake Fluid Effects on Paint and Electrical Components Caution
• Parking Brake Adjustment
• Front Disc Brake Pads Replacement
• Disc Brake Component Specifications
• Brake Rotor Thickness Variation Measurement
• Brake Rotor Assembled Lateral Runout Correction
• Brake Pad and Rotor Burnishing
• Rear Disc Brake Mounting and Hardware Inspection
• Brake Caliper Inspection
• Brake Rotor Thickness Measurement