Installing a New Caliper in a 1995 Cavalier

There were several things that overstayed their welcome through the 1980s and into early 1990s; first thing that comes to mind are hair metal bands and the second is the first generation Cavalier. From its inception in 1982 and continuing through 1994, the Cavalier only underwent mild styling changes to the grille and lighting. In 1995, Chevy finally got with the times and drastically redesigned the Cavalier. The 1995 Cavalier featured a wedge-style body design but used the same 120-horsepower, 2.2-liter engine that the 1994 model used. The 1995 Cavalier came standard with front disc brakes, which use a caliper to press the brake pads against the rotors. Installing a new caliper is a relatively simple task, but you must bleed the brake system afterward.

Instructions

Loosen the lug nuts on the front wheels, using a breaker bar and socket. Lift the front of the cavalier with a floor jack and slide jack stands under its subframe. Lower the vehicle onto the jack stands, remove the lug nuts and pull the wheels off the vehicle.

Clamp the brake hose shut by clamping brake line pliers about halfway up the hose, and lock the pliers. If you do not have brake line pliers, wrap the halfway point of the hose with a thick shop cloth and clamp around the cloth with locking pliers.

Position a drain pan under the caliper and remove the brake line-to-caliper banjo bolt, using a ratchet and socket. Remove the washers from the banjo bolt and discard them.

Remove the caliper mounting bolts, using a ratchet and Allen-bit socket. Pull the caliper upward from its bracket.

Pry downward on one side of the outer brake pads backing plate with a flat-head screwdriver to disengage the locating pin on the pad from the locating hole in the caliper body. Pivot that side of the brake pad from the caliper body. Repeat this step on the other side of the pad to remove it.

Pull the inner brake pad from the caliper. Notice that metal fingers secure it in place inside the caliper pistons cavity.

Align the fingers on the inner brake pad with the new caliper pistons cavity. Press the brake pad toward the piston until it seats in place on the piston.

Line up the outer brake pad with the calipers body and pry upward on one side of the pads, retaining spring with a flat-head screwdriver. Pivot that side of the pad onto the caliper body until its locator pin lines up with the locator hole in the caliper body. Remove the flat-head screwdriver to allow the pin to slide into the holes and secure that side of the pad. Repeat this step on the other side of the brake pad.

Lower the new caliper onto the bracket and hand-tighten the caliper mounting bolts. Tighten the caliper mounting bolts to 38 foot-pounds, using an Allen-bit socket and torque wrench.

Remove the plastic plugs from all the orifices on the new caliper. If needed, hand-thread the new bleeder valve, which comes with the new caliper, into its hole on the rear of the caliper. Torque the bleeder valve to 115 inch-pounds, using an inch-pound torque wrench and socket.

Slide a new brass washer two new washers come with the new caliper onto the banjo bolt and slide the banjo bolt through the end of the brake hose. Install the second washer onto the banjo bolt and thread the banjo bolt into the caliper. Tighten the banjo bolt to 32 foot-pounds.

Remove the brake line pliers or locking pliers and shop cloth from the brake hose.

Press and release the brake pedal two or three times to purge any residual vacuum from the brake booster.

Loosen the rear lug nuts and raise the rear of the Cavalier, using the jack. Slide jack stands under the rear suspension crossmember and lower the vehicle onto the jack stands. Remove the lug nuts and pull the rear wheels off the vehicle.

Fill the master cylinder to the Max line with fresh DOT 3 brake fluid.

Press a 1/4-inch-inside-diameter clear vinyl hose onto the rear passengers side brake bleeder valve, located near the top of the drum backing plate. Set the other end of the hose in a clean, clear container. Pour new DOT 3 brake fluid into the clean, clean container until it covers the end of the hose.

Instruct an assistant to press the brake pedal to the floor and hold it. Open the bleeder valve by turning it counterclockwise with a six-point box-end wrench. Watch for air bubbles to come from the submerged end of the hose. Lightly tighten the bleeder valve. Wait 15 seconds, then repeat this step until no air bubbles come from the hose during the 15-second wait between each repetition.

Tighten the bleeder valve to 115 inch-pounds. Refill the master cylinder with fresh DOT 3 brake fluid.

Repeat steps 4 through 6 to bleed the remaining three wheels, in the following order: drivers rear, passengers front, then drivers front. On the front calipers, the bleeder valve is on the top, rear of the caliper.

Reinstall all four wheels and hand-tighten the lug nuts. Raise the rear of the Cavalier off the jack stands and remove the stands. Lower the rear of the vehicle to the ground. Raise the front of the car off the jack stands and remove the stands. Lower the vehicle to the ground and tighten the lug nuts, in a crisscross pattern, to 100 foot-pounds.

Take any old DOT 3 brake fluid to a used automotive fluid recycler for disposal. Some auto parts stores take old fluids without charge.