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HOMESERVICE MANUALSCHEVROLET2003TRAILBLAZER 4.2 S, 4WDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1452 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE CALIPER OVERHAUL - FRONTASSEMBLY PROCEDURE
2003 Chevrolet TrailBlazer 4.2 S, 4WD

Assembly Procedure

2003 Chevrolet TrailBlazer 4.2 S, 4WDSECTION Assembly Procedure
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Oldsmobile Bravada, 2004 GMC Envoy XUV, 2004 GMC Envoy XL, 2004 GMC Envoy, and 2004 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Exploded View Of Front Brake Caliper
    GM382726Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the new piston seals (3), the caliper bores, and the pistons (2) using clean brake fluid.
  2. Install the piston seals (3). Ensure that the piston seals are not twisted in the caliper bore grooves.
  3. Install the boot seals (1) on the pistons (2).
  4. Install the pistons in the caliper bores.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the bleeder valve (5) in the caliper housing (6).

    Tighten:  Tighten the bleeder valve to 12 N.m (110 lb in).

  6. Install the bleeder valve cap (4).
    7. Fig 2: Installing Boot Seals Into Caliper Housing Bores
    GM537191Courtesy of GENERAL MOTORS CORP.
  7. Install the boot seals into the caliper housing bores using the J 8092  and J 43885  . See Special Tools and Equipment .
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.