Chevrolet Cobalt Service & Repair Manual: Caliper Service

Replacement

1. Raise and support vehicle, then remove tire and wheel assemblies.
2. Install and tighten two wheel nuts opposite to retain rotor to hub.
3. Tighten suitable C-clamp to compress piston into caliper bore.
4. Remove mounting bolt and brake hose from caliper, Fig. 1.
5. Remove and discard copper brake hose gaskets.
6. Cap opening in brake caliper and brake hose.
7. Remove guide pin bolts, caliper and bracket.
8. Reverse procedure to install.

Disassemble

1. Remove caliper piston from bore using compressed air through fluid inlet hole.
2. Remove retaining ring to dust boot of caliper housing, Fig. 2.
3. Remove piston boot seal from counterbore in caliper, then the piston seal using suitable piece of wood, Fig. 3.

Assemble

1. Lubricate new piston seal using suitable DOT 3 brake fluid and install seal into caliper bore.
2. Apply suitable DOT 3 brake fluid to surface area of caliper piston.
3. Install bottom half of caliper piston into caliper bore and dust boot seal over caliper piston, Fig. 4.
4. Compress caliper piston to caliper bore and seat piston boot into counterbore.
5. Install retaining ring and bleeder valve.
6. Install bleeder valve cap and caliper.

Fig. 1 Brake caliper hose removal

Fig. 2 Retaining ring removal

Fig. 3 Piston boot removal

Fig. 4 Caliper piston installation

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