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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 830 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR BRAKE CALIPER REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Locating Caliper Guide Pins & Caliper Guide Pin Bolts
    GM1385046Courtesy of GENERAL MOTORS CORP.
  1. Install the brake caliper to the caliper bracket.
    2. CAUTION: Refer to Fastener Caution .
  2. While using a wrench on the flats of the caliper guide pins (1), install the brake caliper guide pin bolts (2).

    Tighten:  Tighten the bolts to 34 N.m (25 lb ft).

    3. Fig 2: View Of Park Brake Cable
    GM1385058Courtesy of GENERAL MOTORS CORP.
  3. Press the park brake cable end fitting into the bracket on the caliper to secure the retaining tabs (4).
  4. Secure the park brake cable end (1) to the lever on the caliper.
    5. Fig 3: View Of Rear Brake Hose
    GM1385043Courtesy of GENERAL MOTORS CORP.
  5. Remove the caps or plugs from the brake caliper opening and the brake hose (3).
    6. NOTE: Do not reuse the copper brake hose gaskets.
  6. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3).
  7. Install the brake hose and the brake hose-to-brake caliper bolt to the caliper.

    Tighten:  Tighten the bolt to 48 N.m (35 lb ft).

  8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Rear Brake Caliper - Cobalt SS) or Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
  9. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  11. Lower the vehicle.
  12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  13. Slowly release the brake pedal.
  14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  15. Adjust the park brake cable tension. Refer to Parking Brake Adjustment (Disc) or Parking Brake Adjustment (Drum) .
  16. Position the park brake lever boot to the floor console and press the boot retainer into place to secure.
RENDER: 1.0x

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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.