Service or replace brake caliper slide pins and boots to restore proper caliper movement and prevent uneven brake pad wear on the 1966 Corvette's 4-wheel disc brake system.

Warnings

Tools required

Parts

• Brake caliper slide pin kit (includes pins and boots) × 2 — Use OEM specification or Delco equivalent
• High-temperature silicone brake grease × 1 — GM P/N 12377953 or equivalent

Fluids

• DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level ground and engage parking brake.
2. Loosen front wheel lug nuts 1/4 turn before raising vehicle.
3. Raise front of vehicle with floor jack at frame rail and secure on jack stands under designated frame jacking points.
4. Remove front wheels completely.
5. Inspect brake system for fluid leaks, damaged lines, or excessive pad wear before proceeding.
6. Have a container ready to catch any brake fluid drips during service.

Procedure

1. 1

   Remove caliper mounting bolts
   Locate the caliper-to-bracket mounting bolts on the fixed Delco-Moraine caliper. Verify the correct bolt head type and size against the factory service manual for the 1966 Corvette before removal, as this fixed caliper does not use floating-caliper hardware. Support the caliper with one hand as you remove the second bolt to prevent it from falling.
2. 2

   Suspend caliper safely
   Carefully lift the caliper assembly off the brake rotor without allowing it to hang by the rubber brake hose. Use a piece of wire or a bungee cord to suspend the caliper from the suspension spring or frame above. Ensure no tension or strain is placed on the brake hose. Do not disconnect the brake hose unless replacing the caliper itself.
3. 3

   Remove slide pin boots
   Inspect the slide pin boots (rubber dust covers) on the caliper bracket. Using a small pick or your fingers, carefully peel back and remove the rubber boots from each slide pin hole. Note the orientation and seating position of the boots for reinstallation. If boots are torn, cracked, or deteriorated, they must be replaced.
4. 4

   Extract slide pins
   Using pliers or by hand if possible, extract both slide pins from the caliper bracket. The pins should slide out with moderate force. If pins are seized or corroded, apply penetrating oil and allow to soak for 10-15 minutes, then carefully work them free. Avoid damaging the slide pin bores in the bracket.
5. 5

   Clean slide pin bores
   Thoroughly clean the slide pin bores in the caliper bracket using brake parts cleaner and a wire brush. Remove all old grease, rust, corrosion, and debris. Inspect bores for scoring, pitting, or excessive wear. The bores must be smooth for proper slide pin operation. Wipe clean with a lint-free rag and allow to dry completely.
6. 6

   Inspect and clean slide pins
   Inspect the original slide pins for wear, corrosion, scoring, or bending. If pins show any damage or wear beyond light surface oxidation, replace them. Clean reusable pins with brake parts cleaner and a wire brush, ensuring all old grease is removed. Wipe dry with a clean rag.
7. 7

   Apply brake grease to slide pins
   Apply a thin, even coating of high-temperature silicone brake grease to the entire length of each slide pin. Use only brake-specific grease—do not use standard lithium grease or anti-seize compound, as these will deteriorate and cause binding. Ensure complete coverage but avoid excessive grease that can attract contaminants.
8. 8

   Install slide pins
   Insert the greased slide pins into the caliper bracket bores, pushing them fully into position. Pins should slide smoothly with light resistance. If pins bind or require excessive force, remove and re-inspect bores and pins for obstructions or damage. Ensure pins are fully seated in the bracket.
9. 9

   Install new slide pin boots
   Position new rubber boots over each slide pin and press firmly into the groove on the caliper bracket. Ensure boots are fully seated around their entire circumference with no gaps or folded areas. The boot should seal completely to prevent dirt and moisture entry. Pull gently on each boot to verify it is locked in place.
10. 10

    Reinstall caliper
    Remove the support wire and carefully position the caliper back over the brake rotor and onto the mounting bracket. Align the caliper mounting holes with the bracket. If the caliper does not fit over the pads easily, the piston may need to be compressed slightly using a C-clamp (ensure brake fluid reservoir cap is loose to allow fluid displacement).
11. 11

    Install and torque caliper bolts
    Insert both caliper mounting bolts through the caliper and thread into the bracket by hand to prevent cross-threading. Tighten both bolts evenly using a 3/8" hex key. Torque the caliper mounting bolts to the factory-specified value per the 1966 Corvette service manual (verify spec before final tightening). Verify bolts are fully seated and caliper is secure with no movement.
12. 12

    Verify caliper slide operation
    With the caliper installed, manually push the caliper body inward and outward on the slide pins to verify smooth, free movement without binding. The caliper should slide easily along the pins with light hand pressure. Any binding or resistance indicates improper installation or damaged components—do not proceed until corrected.
13. 13

    Repeat for opposite side
    Repeat steps 1 through 12 for the opposite front caliper to ensure both sides have properly serviced slide pins. Consistent maintenance on both sides prevents uneven braking.
14. 14

    Check brake fluid level
    Open the hood and locate the brake master cylinder reservoir. Check the brake fluid level and top off with fresh DOT 3 brake fluid (factory specification) if needed to bring the level to the proper fill mark. Wipe away any spilled fluid immediately. Replace the reservoir cap securely.

Reassembly

1. Reinstall both front wheels and hand-tighten lug nuts in a star pattern.
2. Lower vehicle from jack stands to the ground.
3. Torque wheel lug nuts to 80 ft-lbs in a star pattern with the vehicle on the ground.
4. Remove wheel chocks and release parking brake.

Verification

• Before starting the engine, pump the brake pedal several times until it feels firm and returns to normal height. The first few pumps may feel soft as the system re-seats.
• Start the engine and test brake pedal feel. Pedal should be firm with normal travel. A soft or spongy pedal indicates air in the system and requires bleeding.
• Perform a low-speed test drive in a safe area. Apply brakes gently at 5-10 mph to verify normal operation and equal braking force. Listen for unusual noises.
• Perform several moderate stops from 25-30 mph to seat the brake pads and verify proper caliper sliding action.
• After test drive, visually inspect calipers for fluid leaks, proper pad contact, and equal heating on both sides.
• Re-check wheel lug nut torque after the first 50 miles of driving.
• Monitor brake performance over the next several days. Any pulling, noise, or uneven braking requires immediate inspection.

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