Buick Regal: Front Brake Caliper Overhaul (J60)

Disassembly Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

WARNING: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.

CAUTION: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

1. Front Brake Caliper - Remove.

2.

Bleeder Valve (1) and Cap (2) - Remove.

3.

NOTE: Direct low-pressure, compressed air through the brake caliper fluid inlet.

Brake Caliper Piston (1) - Remove.

4. Brake Caliper Piston Dust Boot (2) - Remove and DISCARD.

5.

NOTE: Use a wooden or plastic tool to remove the seal.

Brake Caliper Piston Seal (1) - Remove and DISCARD.

6. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.

7. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.

8. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.

9. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air.

NOTE: Do NOT use abrasives to clean the brake caliper piston.

10. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist.

11. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion.

Replace the caliper assembly if any of these conditions exist.

Assembly Procedure

1.

Lubricate the NEW caliper piston seal with brake fluid from a clean, sealed brake fluid container.

2. Brake Caliper Piston Seal (1) - Install.

3. Apply a thin coat of brake fluid from a clean, sealed brake fluid container to the brake caliper bore.

4.

NOTE: Seat the NEW caliper piston dust boot in the groove of the brake caliper piston.

Brake Caliper Piston (1)@ Brake Caliper Piston Dust Boot (2) - Install.

5. Compress the caliper piston to the bottom of the caliper bore.

6. Fully seat the piston dust boot seal into caliper counterbore.

7.

CAUTION: Fastener Caution.

Bleeder Valve (1) - Install 10 N.m (89 lb in).

8. Cap (2) - Install.

9. Front Brake Caliper - Install.

FRONT BRAKE CALIPER OVERHAUL (JQ5)

Disassembly Procedure

WARNING: Brake Dust Warning.

WARNING: Brake Fluid Irritant Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Remove the brake caliper from the vehicle.

2.

WARNING: Caliper Piston Removing Warning.

CAUTION: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.

CAUTION: Do not remove the caliper external crossover tube or separate the 2 caliper halves. If the crossover tube and/or the caliper halves are separated, corrosion and damage to the caliper may result.

NOTE: Remove only one side of caliper pistons at a time. Use a wooden block and tie straps to secure the pistons on the non-removal side.

Remove the brake caliper pistons from the caliper bores by carefully directing low pressure compressed air (1) into the caliper through a fluid inlet hole.

3.

Remove the piston dust boot seals (3) from the seal counterbores in the caliper. Discard the dust boot seals (3).

4. Remove the bleeder valve caps (1).

5. Remove the bleeder valves (2).

6. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bores, replace the caliper assembly.

7. If light rust or light corrosion are present in the caliper bores, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.

NOTE: Do not use abrasives to clean the brake caliper pistons.

8. Clean the brake caliper piston bores and seal counterbores, and the caliper pistons (4) with denatured alcohol, or equivalent.

9. Dry the caliper piston bores and counterbores, and the pistons (4) with non-lubricated, filtered, compressed air.

10. Inspect the caliper pistons (4) for cracks, scoring, and/or damage to the plating. Replace the caliper pistons (4) if any of these conditions exist.

11. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion.

Replace the caliper assembly if any of these conditions exist.

Installation Procedure

1.

Lubricate the cleaned caliper pistons (4) with a thin coat of brake fluid from a clean, sealed brake fluid container.

NOTE: Caliper pistons, and piston dust boot seals are of different sizes and are not interchangeable. Use care when reassembling.

2. Install the new caliper piston dust boot seals (3) over the caliper pistons (4) and make sure that the dust boots outer lips seat properly into the pistons grooves.

NOTE: Caliper pistons, and piston dust boot seals are of different sizes and not interchangeable. Use care when reassembling.

3. Install the bottom half of the caliper pistons (4) into the caliper bores.

4. Compress the caliper pistons (4) to the bottom of the caliper bores.

5. Fully seat the caliper piston dust boot seals (3) into the caliper counterbores.

CAUTION: Fastener Caution.

6. Install the bleeder valves (2) to the caliper and tighten them to 17 N.m (13 lb ft).

7. Install the bleeder valve caps (1).

8. Install the brake caliper to the vehicle.

FRONT BRAKE CALIPER BRACKET REPLACEMENT

Special Tools

EN-45059 Angle Meter

Equivalent regional tools: Special Tools.

WARNING: Brake Dust Warning.

Removal Procedure

1. Raise and support the vehicle.

2. Remove the front tire and wheel assembly.

CAUTION: Brake Caliper Supporting to Prevent Hose Damage Caution.

NOTE: Do NOT disconnect the brake hoses from the calipers.

3. Remove the brake caliper assembly and support with heavy mechanics wire.

4. Front Disc Brake Pad & Front Disc Brake Pad Retaining Spring - Remove.

5.

NOTE: The upper guide pin has a bevel (arrow).

Front Brake Caliper Guide Pin- Upper(1) - Remove.

6. Front Brake Caliper Guide Pin- Lower(2) - Remove.

7. Front Brake Caliper Guide Pin Seal(3) - Remove[2x].

8.

Front Brake Caliper Bracket Bolt(1) - Remove[2x].

9. Front Brake Caliper Bracket(2) - Remove.

Installation Procedure

1. Prepare the brake caliper bracket bolts and the bracket threaded holes for assembly:

• Re-cut the bolt threads.
• Re-cut the threaded holes.
• Thoroughly clean the residue from the bolt threads with denatured alcohol or equivalent and allow to dry.
• Thoroughly clean the residue from the threaded holes with denatured alcohol or equivalent and allow to dry.
• Apply thread lock agent to 2/3 of the threaded length of the bolts.

2.

Front Brake Caliper Bracket(2) - Install.

CAUTION: Fastener Caution.

3. Front Brake Caliper Bracket Bolt(1) - Install and tighten[2x].

1. First Pass: 150 N.m (111 lb ft)
2. Final Pass: 15 - 30 degrees - Use the special tool: EN-45059 meter

4.

Front Brake Caliper Guide Pin Seal(3) - Install[2x].

5. Apply a thin coat of special guide pin grease to the guide pins and insert a small amount of this grease into the guide pin holes.

NOTE:

• The upper guide pin has a bevel (arrow).
• Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
• Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

6. Front Brake Caliper Guide Pin- Upper(1) - Install

NOTE:

• Ensure the brake caliper guide pin seal is fully seated in the groove of the brake caliper guide pin and the guide pin slides freely in caliper bracket bore.
• Gently lift the edge of the guide pin seal while pushing the guide pin into the caliper bracket bore to expel any trapped air.

7. Front Brake Caliper Guide Pin- Lower(2) - Install.

8. Front Disc Brake Pad & Front Disc Brake Pad Retaining Spring - Install.

9. Front Brake Caliper - Install.

10. Install the front tire and wheel assembly.

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