Spark

Front Disc Brake Mounting and Hardware Inspection

Warning: Refer to Brake Dust Warning in the Preface section.

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 to Lifting and Jacking the Vehicle
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
6. Grasp the brake calliper housing and try to move the brake calliper housing up/down and forward/reverse in relation to the brake calliper mounting bracket (3). If excessive looseness is observed the brake calliper bracket bushes and/or the brake calliper mounting bolts may need to be replaced.
7. Compress the front calliper pistons.

•	Install a large C-clamp over the top of the calliper housing and against the back of the outboard pad (1).

•	Slowly tighten the C-clamp until the pistons are pushed completely into the calliper bores.

•	Remove the C-clamp from the calliper.

8. With the pistons compressed into the calliper bores, grasp the brake calliper housing and slide it back and forth on the brake calliper mounting bolts. Check for smooth operation. If the brake calliper housing slide force is high or the brake calliper housing does not slide smoothly, inspect the brake calliper mounting bolts and/or the brake calliper mounting bracket bushes for wear or damage. If wear or damage conditions are found, replacement of the brake calliper mounting bolts and/or the brake calliper mounting bracket bushes is necessary.
9. Remove the brake calliper mounting bolts from the brake calliper mounting bracket and support the brake calliper using heavy mechanics wire. Do not remove the hydraulic brake hose from the calliper. Refer to Front Brake Caliper Replacement .
10. Remove the disc brake pads (1, 4) from the brake caliper mounting bracket (3).
11. Inspect the disc brake pad mounting hardware for the following:

•	Missing mounting hardware

•	Excessive corrosion

•	Bent mounting tabs (2)

•	Looseness at the brake caliper mounting bracket (3)

•	Looseness at the disc brake pads (1, 4)

•	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 calliper mounting bracket, yet slide easily on the mounting hardware without binding.



14. Inspect the calliper 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 calliper mounting hardware requires replacement.
16. Install the disc brake pads to the brake calliper mounting bracket.
17. Install the disc brake calliper to the brake calliper mounting bracket. Refer to Front Brake Caliper Replacement .