Originally introduced in 1964, the Chevrolet Malibu base model for 2004 came equipped with a 2.2.-liter in-line four-cylinder engine. A 3.5-liter V-6 was an optional upgrade for all three trim levels of the 2004 Malibu. The 2004 Malibu was produced with front wheel ventilated disc brakes. This brake system consists of a caliper, caliper bracket, rotor and brake pads on both sides of the car. Brake pads wear differently depending upon the upkeep of the vehicle and the type of driving the car experiences.
Instructions
- 1
Open the hood of the Malibu. Check the brake-reservoir fluid level. If the brake fluid is already at the "Full" mark, remove brake fluid with a turkey baster or siphon until the fluid is about 1/2-inch below the "Full" mark. If the fluid level is already below the full mark, disregard this step and proceed to Step 2 of this project.
2Loosen the front wheel lug nuts with a tire iron. Lift the front of the Malibu with a jack. Place jack stands beneath the front frame rails. Lower the car onto the jack stands carefully. Remove the wheel lug nuts completely with the tire iron, and then remove both front wheels. Spin one lug nut onto the face of the rotor on either side of the car, to hold the rotor in place during the replacement of the brake pads.
3Insert a small pry bar into the opening on the outer body of the brake caliper. Pry the inboard brake pad (behind the rotor) inward as far as you can with the pry bar. Remove the caliper-mounting bolts from the inward facing side of the caliper, with a ratchet and socket. Remove the caliper from the brake assembly, using the pry bar if necessary. Hang the caliper from the front strut spring with a metal clothes hangar or thin metal hook. Do not let the caliper hang by its attached rubber hose.
4Remove the old brake pads from the caliper-mounting bracket. Insert one of the old brake pads against the caliper piston on the inside rear of the caliper. Attach a large C-clamp around the old brake pad and the outer backside of the caliper. Slowly turn the C-clamp clockwise to compress the caliper piston completely. Remove the C-clamp and old pan when you have compressed the caliper.
5Inspect the front brake rotor. Look at the outer and inner face of the rotor for deep grooves, rusting or pitting. If the rotors are scarred badly, replace them as well. Acquire the rotor's thickness by measuring across its top edge. Use a rotor micrometer if you have one or a regular tape measure if a rotor micrometer is not available. The minimum thickness of the rotor should be 0.906 (in ten-thousandths of an inch) for a micrometer reading, or 7/8-inches if using a tape measure.
6Lightly lubricate the metal shims attached to the caliper bracket, using caliper grease. Lubricate the small indents where the brake pad ends are inserted against the shims. Install the brake pads onto the caliper bracket, ensuring the pad with the "L" shaped metal protrusion is on the inside, behind the rotor. There are two pads in a set with an "L" shaped wear indicator, and two without.
7Pull the caliper slides out of the backside of the caliper with your fingers. The slides are the small metal tubes that the caliper-mounting bolts attach to when the brakes are assembled. Lubricate each caliper slide thoroughly with caliper grease. Insert the slides back into the rear of the caliper.
8Install the front caliper back onto the brake assembly. Insert and tighten the caliper-mounting bolts to 26 foot-pounds with a 1/2-inch drive torque wrench and socket.
9Repeat Steps 2 through 7 to complete the replacement of the brake pads on the second side of the car. Remove the single lug nut from the faces of each rotor, only after you have double-checked the torque on the caliper-mounting bolts.
10Install the front wheels back onto the Malibu, and snug the lug nuts up with the tire iron. Raise the Malibu off the jack stands, and then remove the jack stands from beneath the car. Lower the car to the ground. Tighten the front wheel lug nuts to 100 foot-pounds final torque with the torque wrench and a socket.
11Immediately proceed to the driver's seat of the vehicle. With the car off, slowly pump the brake pedal approximately 10 to 15 times. The pedal should become stiff or harder to depress. If the pedal does not become stiff after 15 times of pumping, bleed the brake calipers.
12Check the brake fluid level in the reservoir. Add brake fluid as needed to fill the brake fluid reservoir to the "Full" mark.
