Volt

Rear Brake Calliper Replacement

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

Warning: Refer to Brake Fluid Irritant 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 .
3. Disable the hand brake cable adjuster. Refer to Hand brake Cable Adjuster Disabling .



4. Disconnect the hand brake cable (1) from the actuator lever.
5. Compress the hand brake cable conduit retainers (2).
6. Remove the hand brake cable from the cable bracket and position the hand brake cable aside.



7. Remove the brake hose fitting bolt (1).

Note: Do not reuse the brake hose fitting gaskets.

8. Remove and discard the brake hose fitting gaskets (2) from the brake hose (3).
9. Plug the brake hose fitting to prevent brake fluid loss and contamination.




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.

10. Using a backup wrench to hold the brake calliper guide pin (1) stationary, remove the brake calliper guide pin bolts (2).
11. Remove the brake calliper.

1. Position the brake calliper over the brake pads and to the calliper bracket.

Caution: Refer to Fastener Caution in the Preface section.

2. Using a backup wrench to hold the brake calliper guide pin (1) stationary, install the brake calliper guide pin bolts (2) and tighten to 28 N·m (21 lb ft).



3. Assemble the brake hose fitting bolt (1) and the 2 new brake hose fitting gaskets (2) to the brake hose (3).
4. Install the brake hose assembly to the brake calliper and tighten the fitting bolt to 40 N·m (30 lb ft).



5. Insert the hand brake cable through the hand brake cable bracket on the brake calliper.
6. Connect the hand brake cable (1) to the actuator lever and engage the hand brake cable conduit retainers (2) to the cable bracket.
7. Enable the hand brake cable adjuster. Refer to Hand brake Cable Adjuster Enabling .
8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding : Pressure .
9. Install the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .