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HOMESERVICE MANUALSCHEVROLET2008HHR SS, STANDARDREPAIR AND DIAGNOSIS (SINGLE PAGE)BRAKESMECHANICAL - HYDRAULICDISC BRAKE SYSTEMREPAIR INSTRUCTIONSREAR DISC BRAKE PADS REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet HHR SS, Standard

Removal Procedure

2008 Chevrolet HHR SS, StandardSECTION Removal Procedure
  1. Inspect the fluid level in the brake master cylinder reservoir.
  2. If the brake fluid level is midway between the maximum full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If the brake fluid level is higher than midway between the maximum full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  7. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
    8. NOTE: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism.
  8. Tighten the C-clamp just enough to compress the caliper piston 1 mm (0.039 in) of travel only.
  9. Remove the C-clamp from the caliper.
    10. Fig 1: Locating Caliper Guide Pins & Caliper Guide Pin Bolts
    GM1385046Courtesy of GENERAL MOTORS CORP.
  10. While using a wrench on the flats of the brake caliper guide pins (1), remove the brake caliper guide pin bolts (2).
    11. NOTE: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
  11. Without disconnecting the hydraulic brake flexible hose, remove the caliper from the mounting bracket and secure the caliper with heavy mechanics wire or equivalent.
    12. Fig 2: Identifying Brake Pad Retainers & Caliper Bracket - Rear
    GM1385048Courtesy of GENERAL MOTORS CORP.
  12. Remove the brake pads from the caliper mounting bracket.
  13. Remove the brake pad retainers (1) from the caliper bracket.
  14. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (2) of any debris and corrosion.
  15. Inspect the brake caliper guide pins for freedom of movement and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:
    • Restricted caliper guide pin movement
    • Looseness in the brake caliper mounting bracket
    • Seized or binding caliper guide pins
    • Split or torn boots
  16. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
    17. Fig 3: Retracting Piston Into Caliper Bore
    GM1365685Courtesy of GENERAL MOTORS CORP.
  17. Using a spanner wrench type caliper piston installer, fully retract the piston into the caliper bore.
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.