Volt

Front Brake Calliper Bracket Replacement

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

Danger: Do not use a service jack in locations other than those specified to lift this vehicle. Lifting the vehicle with a jack in those other locations could cause the vehicle to slip off the jack and roll; this could cause injury or death.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .




Note: 

•	DO NOT use any air tools to remove or install the guide pin bolts. Use hand tools ONLY.

•

Install an open end wrench to hold the calliper guide pin in line with the brake calliper while removing or installing the calliper guide pin bolt. DO NOT allow the open end wrench to come in contact with the brake calliper. Allowing the open end wrench to come in contact with the brake calliper will cause a pulsation when the brakes are applied.

3. Hold the brake calliper guide pin stationary and remove the brake calliper guide pin bolts (1).

Caution: Support the brake calliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the calliper in this manner will cause the flexible brake hose to bear the weight of the calliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

4. Remove the brake calliper and support with heavy mechanics wire or equivalent.




Note: Note the location of the wear sensor for correct installation.

5. Remove the inner brake pad (1).
6. Remove the outer brake pad (2).



7. Remove the brake pad springs (1).




Note: The upper brake calliper guide pin is equipped with a bushing and must be installed in the same location.

8. Remove the upper brake calliper guide pin (1).
9. Remove the lower brake calliper guide pin (2).
10. Remove the 2 brake calliper guide pin seals.




Note: Do not reuse the brake calliper bracket bolts.

11. Remove and discard the brake calliper bracket bolts (1).



12. Remove the brake calliper bracket (1).

1. Install the brake calliper bracket (1).

Caution: Refer to Fastener Caution in the Preface section.




2. Install 2 new brake calliper bracket bolts (1).

2.1.	Tighten the bolts a first pass to 100 N·m (74 lb ft).

2.2.	Tighten the bolts a second pass an additional 60 degrees.

2.3.	Tighten the bolts a final pass an additional 15 degrees.




3. Install the brake pad springs (1).



4. Install the 2 brake calliper guide pin seals.
5. Ensure the brake calliper guide pin seals are fully seated in the groove of the brake calliper bracket.

Note: The upper brake calliper guide pin is equipped with a bushing and must be installed in the same location.

6. Install the upper brake calliper guide pin (1).
7. Install the lower brake calliper guide pin (2).
8. Ensure the brake calliper guide pin seals are fully seated in the groove of the brake calliper guide pins.




Note: Note the location of the wear sensor for correct installation.

9. Install the inner brake pad (1).
10. Install the outer brake pad (2).
11. Position the brake calliper over the brake pads and to the calliper bracket.



12. Using a backup wrench to hold the brake calliper guide pin stationary, install the brake calliper guide pin bolts (1) and tighten to 28 N·m (21 lb ft).
13. Install the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .