Volt

Front Brake Disc Replacement

Special Tools

For equivalent regional tools, refer to Special Tools .

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 reuse the brake calliper bracket bolts.

3. Remove and discard the brake calliper bracket 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 bracket as an assembly and support with heavy mechanics wire or equivalent.



5. Remove the brake disc bolt (1).



6. Remove the brake disc (1).

1. If installing a new brake disc, clean the friction surfaces of the brake disc with denatured alcohol or equivalent.
2. Using the CH-42450-A Wheel Hub Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
3. Using the CH-41013 Disc Resurfacing Kit , thoroughly clean any rust or corrosion from the mating surface of the disc to the hub/axle flange.



4. Install the brake disc (1).

Caution: Refer to Fastener Caution in the Preface section.




5. Install the brake disc bolt (1) and tighten to 9 N·m (80 lb in).
6. Position the brake calliper and bracket assembly over the brake disc and to the steering knuckle.




Note: Do not reuse the brake calliper bracket bolts.

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

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

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

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

8. Install the tyre and wheel assembly. Refer to Tyre and Wheel Removal and Installation .