How to Replace a Caliper in a Pontiac Bonneville

Replacing a brake caliper is even more difficult than on other model cars. This is for two main reasons. The Bonneville has been discontinued, and the removal and installation process varies for its front and rear calipers.

Instructions

Removing an Old Caliper

1

Check the brake fluid level in the master cylinder reservoir. Remove fluid to the midway point between the maximum and minimum levels if the fluid level is above this point.

2

Raise and stabilize the vehicle with a jack stand suitable for a Bonneville. Remove the wheel for the caliper that must be replaced. Screw two of the lug nuts back onto the rotor to keep it on the hub.

3

Go to the front parking brake cable on the rear caliper if this is one you are replacing. Pull down on the cable and remove it from the park brake cable connector.

4

Compress the caliper piston into the bore with a C-clamp. Place the clamp over the top of the caliper housing and against the outboard brake pad's back end. Don't make the piston travel further than a millimeter.

5

Disconnect the brake hose by removing the caliper bolt. Toss away the two copper gaskets. Plug the hose and the opening in the caliper with rubber.

6

Detach the parking brake cable bracket from the caliper. Remove the parking brake cable from the parking brake lever on the caliper while leaving the cable attached to the cable bracket.

7

Remove the caliper, starting with the pin bolts. This procedure varies depending on a front or rear caliper.

Installing a New Caliper

8

Wipe the old grease from the pin bolts and apply a fresh, thin cost. Don't grease the bolt treads, though, nor to any part of the brake pad hardware.

9

Install the replacement brake caliper and pin bolts, using the reverse procedure as removal. For rear calipers, this means installing it to the upper pin bolt and rotating it down over the brake pads.

10

Connect the brake hose onto the caliper, unplugging all the openings first. Use new gaskets with the bolt.

11

Reconnect all parking brake components to the rear caliper if needed. This includes connecting the brake cable to the lever on the caliper, the cable bracket to the caliper and the front park brake cable to the cable connector

12

Bleed the brake system. Attach a rubber hose to the open bleeder valve and place the other end in a container of brake fluid. Have an assistant slowly depress the pedal multiple times until all air is removed from the system.

13

Set the brakes while the engine is off. Push the pedal two-thirds of the way down and slowly release it. Repeat this at 15-second intervals until the brakes feel firm.

14

Replace the wheel, removing the lug nuts first that were supporting the rotor to the hub.