Brake Rotor - Rear Single

This procedure covers the replacement of a single rear brake rotor on a 2023 Chevrolet Bolt EUV, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — ACDelco or OEM equivalent for 2023 Bolt EUV
• Rotor set screw (if corroded) × 1 — M6 x 1.0 set screw

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
4. Lift rear of vehicle using floor jack at designated jacking point
5. Secure vehicle on jack stands rated for vehicle weight (4,000+ lbs)
6. Remove rear wheel completely
7. Inspect brake system for any leaks, damage, or abnormal wear on both sides
8. Measure rotor thickness on both rear rotors to verify replacement necessity and matching thickness

Procedure

1. 1

   Compress brake caliper piston
   Before removing the caliper, use a C-clamp or brake piston tool to slowly compress the caliper piston back into its bore. This prevents brake fluid overflow and makes caliper removal easier. Place the clamp on the outboard brake pad and the back of the caliper body. Compress slowly and watch the brake fluid reservoir - it should not overflow. If fluid is at MAX line, remove some fluid with a turkey baster or syringe first.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Using the appropriate socket, remove both slide pin bolts completely. Note the location and condition of any rubber boots or seals on the pins. Keep track of which bolt came from which position if they differ.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Remove and support brake caliper
   Carefully lift the brake caliper off the rotor and caliper bracket. Do NOT let the caliper hang by the brake hose - this will damage the hose. Use a caliper hanger, strong wire, or bungee cord to suspend the caliper from the suspension or chassis. Ensure no stress is placed on the brake line.
   ⚠Never allow brake caliper to hang by the brake hose. This can cause internal hose damage and brake failure.
4. 4

   Remove caliper bracket
   Locate the two caliper bracket bolts that secure the bracket to the steering knuckle/hub assembly. These are typically larger bolts behind where the caliper was mounted. Remove both caliper bracket bolts completely using the appropriate socket. Remove the caliper bracket assembly completely, including any anti-rattle clips or shims. Note their positions for reassembly.
   Torque spec

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

   Remove rotor set screw
   Locate the rotor set screw on the face of the rotor (if equipped - typically a small Phillips screw). Apply penetrating oil if corroded. Use a Phillips screwdriver or impact driver to remove the set screw. If stripped or seized, it may be drilled out carefully. This screw is not critical for rotor retention once wheel is installed.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
6. 6

   Remove old brake rotor
   Pull the brake rotor straight off the wheel hub. If rotor is stuck due to rust or corrosion, tap gently around the edges with a rubber mallet. DO NOT hit the rotor face. If severely stuck, apply penetrating oil around the hub center and let sit for 15 minutes, then retry. Some rotors have threaded holes for a puller if necessary.
7. 7

   Clean hub surface
   Use a wire brush to thoroughly clean all rust, corrosion, and debris from the wheel hub mounting surface. The hub face must be completely clean and flat for proper rotor seating. Clean the wheel stud threads as well. Wipe clean with brake cleaner and allow to dry.
8. 8

   Install new brake rotor
   Remove any protective coating from the new rotor using brake cleaner - spray both sides of the friction surfaces. Apply a thin layer of anti-seize compound to the hub center bore (NOT the friction surfaces). Slide the new rotor onto the hub, ensuring it seats completely flat against the hub face. Rotate the rotor to check for any binding or wobble.
   ⚠New rotors have a protective oil coating that MUST be removed with brake cleaner before installation. Failure to do so will cause poor braking and noise.
9. 9

   Install rotor set screw
   Install the rotor set screw (new or existing if in good condition) to temporarily hold the rotor in place during reassembly. Torque to specification. Do not over-tighten as these screws are easily stripped.
   Torque spec

   Rotor Set Screws7 Nm (5 lb-ft)
10. 10

    Reinstall caliper bracket
    Clean caliper bracket bolt threads with a wire brush. Position the caliper bracket over the rotor and align bolt holes with the steering knuckle. Install both caliper bracket bolts and hand-tighten. Torque both bolts to specification in an alternating pattern (top, then bottom, then verify both).
    Torque spec

    Bracket Bolts102 Nm (75 lb-ft)
11. 11

    Inspect and prepare caliper slide pins
    Inspect caliper slide pins for damage, corrosion, or worn boots. Clean slide pins thoroughly and apply fresh silicone brake grease to the pins per torque specification notes. Ensure rubber boots are intact and properly seated.
12. 12

    Reinstall brake caliper
    Remove caliper from its hanging position. Carefully position the caliper over the brake pads and rotor, aligning the slide pin bolt holes. Install both slide pin bolts and hand-tighten. Apply medium-strength threadlocker to the bolt threads as specified. Torque both slide pin bolts to specification.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
13. 13

    Reinstall wheel and torque lug nuts
    Clean the wheel mounting surface on the rotor hat. Mount the wheel onto the hub, aligning lug nut holes. Install all lug nuts by hand, threading them on straight. Tighten lug nuts in a star pattern by hand, then lower vehicle until tire just touches ground (still supported mostly by jack). Torque lug nuts to specification in a star pattern in three stages: 50%, 75%, then 100% torque.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
14. 14

    Bed-in new rotor and final checks
    Lower vehicle completely and remove jack stands. Before driving, pump brake pedal several times until firm pedal is achieved. Check brake fluid level in reservoir and top off if needed with DOT 4 brake fluid. Test brake operation at low speed in a safe area. New rotors require a bed-in procedure: perform 6-10 moderate stops from 30-40 mph with gradual braking, allowing 30 seconds between stops to cool. Avoid aggressive braking for the first 200 miles.
    ⚠️Before moving vehicle, pump brake pedal until firm. Test brakes at low speed in a safe area before returning to normal driving.

Reassembly

1. Ensure all caliper bracket bolts are torqued to 102 Nm (75 lb-ft)
2. Ensure caliper slide pin bolts are torqued to 35 Nm (26 lb-ft) with threadlocker applied
3. Verify brake caliper is properly supported and not hanging by brake line
4. Confirm wheel lug nuts are torqued to 190 Nm (140 lb-ft) in star pattern
5. Pump brake pedal until firm before driving vehicle

Verification

• Pump brake pedal 10-15 times - pedal should be firm and hold pressure
• Check brake fluid reservoir level - should be between MIN and MAX lines
• Inspect for any brake fluid leaks around caliper and connections
• Verify wheel lug nuts are properly torqued with torque wrench in star pattern
• Test drive at low speed in safe area - brakes should engage smoothly without pulsation or noise
• After test drive, check all fasteners again and verify no leaks
• Verify parking brake operation is normal
• Measure brake rotor runout with dial indicator if available - should be less than 0.05mm
• Complete bed-in procedure: 6-10 moderate stops from 30-40 mph with cooling periods between stops

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