Brake Caliper Bracket

This procedure covers the removal and installation of the brake caliper bracket on a 2023 Chevrolet Bolt EUV, requiring brake system disassembly and bleeding.

Warnings

Tools required

Parts

• Brake caliper bracket × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification
• Brake pads (if replacing) × 1 — Use OEM specification

Fluids

• ACDelco DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Ensure vehicle is in Park mode and powered OFF
3. Loosen wheel lug nuts 1/4 turn while vehicle is still on ground
4. Raise vehicle with floor jack at manufacturer-specified jacking point
5. Support vehicle securely with jack stands rated for vehicle weight
6. Remove wheel completely and set aside
7. Spray caliper bracket bolts and slide pins with penetrating oil if corrosion is present
8. Open brake fluid reservoir cap slightly to allow fluid displacement during caliper compression
9. Have brake fluid catch container ready beneath work area

Procedure

1. 1

   Remove brake caliper from bracket
   Locate the caliper slide pin bolts on the rear of the caliper assembly. Remove both caliper slide pin bolts using appropriate socket. Carefully lift the caliper off the bracket and brake pads. Do NOT let the caliper hang by the brake hose - support it with a caliper hanger or secure it to the suspension with wire to prevent brake line damage.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Disconnect brake hydraulic line (if bracket requires line removal)
   Place a drain pan beneath the caliper. Using a brake line wrench (never use standard wrenches), carefully loosen the banjo bolt connecting the brake hose to the caliper. Remove the banjo bolt completely and immediately plug the brake line opening with a clean rubber cap or plug to prevent fluid loss and contamination. Discard the old copper crush washers - they must be replaced. Expect brake fluid spillage.
   ⚠Brake fluid will drain from the line. Have a container ready and work quickly to minimize fluid loss and air entry into the system.
   Torque spec

   Brake Hose Banjo Bolt41 Nm (30 lb-ft)
3. 3

   Remove brake pads and hardware
   Remove the brake pads from the caliper bracket by sliding them out of the bracket slots. Note the orientation and position of any anti-rattle clips, shims, or pad wear indicators for reassembly. Remove any pad retaining clips or hardware from the bracket. Inspect pads for wear and replace if necessary.
4. 4

   Remove caliper bracket from knuckle
   Locate the two caliper bracket bolts that secure the bracket to the steering knuckle. These are typically larger bolts located behind where the brake rotor sits. Using appropriate socket, remove both caliper bracket bolts completely. The bracket may be tight against the knuckle - tap gently with plastic mallet if needed. Remove the bracket from the vehicle.
   ⚠These bolts are torqued to 120 Nm (88 lb-ft) and may require significant force to break loose. Ensure proper socket engagement to avoid rounding bolt heads.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
5. 5

   Inspect and clean mounting surfaces
   Inspect the caliper bracket for cracks, excessive wear, or damage. Check the brake pad slide surfaces for grooves or corrosion. Inspect the mounting surface on the steering knuckle for damage or thread issues. Use a wire brush to clean the knuckle mounting surface, removing all rust, debris, and old thread locker. Clean the bracket bolt threads and knuckle bolt holes.
6. 6

   Install new or serviced caliper bracket
   Apply medium-strength thread locker to the caliper bracket bolt threads as recommended. Position the new or serviced bracket onto the steering knuckle, aligning the bolt holes. Start both bracket bolts by hand to ensure proper thread engagement. Using a torque wrench, tighten the caliper bracket bolts to specification in an alternating pattern (tighten one partially, then the other, then torque to final spec).
   ⚠️Proper torque on bracket bolts is CRITICAL. Under-torquing can allow the bracket to loosen during braking. Over-torquing can strip threads or crack the bracket.
   Torque spec

   Bracket Bolts102 Nm (75 lb-ft)
7. 7

   Reinstall brake pads and hardware
   Clean the pad slide areas on the bracket with brake cleaner. Apply a thin layer of silicone brake grease to the pad slide surfaces on the bracket (not on friction material). Reinstall any anti-rattle clips or shims in their original positions. Install brake pads into the bracket slots, ensuring proper orientation with friction material facing the rotor.
8. 8

   Compress caliper piston
   Before installing the caliper, the piston must be compressed to accommodate the new or existing brake pads. Using a C-clamp or brake piston compression tool, slowly compress the caliper piston fully into its bore. Monitor the brake fluid reservoir - it will rise as the piston is compressed. Remove excess fluid with a turkey baster if necessary to prevent overflow.
   ⚠Compress piston slowly to avoid damaging internal seals. Never force the piston at an angle.
9. 9

   Reconnect brake hydraulic line
   Remove the plug from the brake line. Install NEW copper crush washers on both sides of the banjo fitting. Position the brake hose banjo fitting onto the caliper inlet port, ensuring proper alignment. Insert the banjo bolt and hand-tighten. Using a brake line wrench and torque wrench, tighten the banjo bolt to specification. Verify the brake hose is not twisted or kinked.
   ⚠️ALWAYS use NEW copper crush washers. Reusing old washers will cause brake fluid leaks and potential brake failure.
   Torque spec

   Brake Hose Banjo Bolt41 Nm (30 lb-ft)
10. 10

    Reinstall brake caliper
    Apply silicone brake grease to the caliper slide pin shafts (not the threads). Position the caliper over the brake pads and bracket, aligning the slide pin bolt holes. Insert both caliper slide pin bolts and hand-tighten. Using a torque wrench, tighten the slide pin bolts to specification.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Bleed brake system
    Attach a clear tube to the brake bleeder screw and submerge the other end in a container of fresh brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/2 turn to release fluid and air, then close before the pedal reaches the floor. Repeat until no air bubbles appear in the discharged fluid. Top off the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid.
    ⚠️Proper bleeding is ESSENTIAL. Air in the brake system will cause spongy pedal feel and reduced braking performance, potentially causing accidents.
    ⚠Never allow the brake fluid reservoir to run dry during bleeding, as this will introduce more air into the system.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Clean the wheel hub surface and wheel mounting surface. Position the wheel onto the hub, aligning the lug holes. Install all lug nuts by hand. Using a torque wrench, tighten lug nuts to specification in a star pattern (cross pattern for 5-lug wheels). Remove jack stands and carefully lower the vehicle to the ground. With the vehicle on the ground, re-torque lug nuts in the same star pattern to ensure proper seating.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure brake fluid reservoir is filled to MAX line with fresh DOT 4 brake fluid
2. Verify all hydraulic connections are tight and free of leaks
3. Double-check that all torque specifications have been met, especially critical brake components
4. Ensure brake hose is not twisted, kinked, or contacting any suspension components through full steering range
5. Pump brake pedal several times until firm pedal feel is achieved before attempting to drive

Verification

• Start the vehicle and verify the brake warning light is OFF on the dashboard
• With the vehicle stationary, firmly apply the brake pedal - it should feel firm and not sink to the floor
• Inspect all brake line connections for fluid leaks while an assistant applies brake pressure
• Perform a low-speed brake test in a safe area to verify proper braking function before normal driving
• Test brakes at increasing speeds in a safe area, ensuring straight stops with no pulling to either side
• After 50-100 miles of driving, re-check all torque specifications and inspect for any fluid leaks
• Listen for any unusual noises during braking (grinding, squealing beyond normal pad break-in)
• If brake pedal feels spongy or travels too far, repeat bleeding procedure - air may still be present in the system

Related trouble codes on this vehicle

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