1996 Chevrolet Caprice Brake Service (ONLINE REPAIR MANUALS)

Caliper Removal

• Siphon enough brake fluid out of master cylinder to bring fluid level to ^1/3 full to avoid fluid overflow when caliper piston is pushed back into its bore.
• Raise vehicle and remove front wheels.
• Using a C-clamp, as illustrated in Fig. , push piston back into its bore.
• If caliper assembly is to be serviced, remove inlet fitting attaching bolt, copper washer, and inlet fitting from caliper housing. Plug opening in inlet fitting to prevent fluid loss and contamination. Do not crimp brake hose, as this may damage internal structure of hose. If only shoe and lining assemb...

Removal

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. If brake drum is rusted or corroded to axle flange and cannot be removed, lightly tap axle flange to drum mounting surface with a suitable hammer.
• Using brake spring pliers or equivalent, unhook primary and secondary return springs, Figs. through . Observe location of brake parts being removed to aid during installation.
• Remove brake hold-down springs with suitable tool.
• Lift actuating leve...

This rear caliper, Fig. , consists of a single piston and an aluminum housing which is suspended in a mounting bracket through two slide pins. Hydraulic pressure, created by applying force to the brake pedal, acts equally against the piston and the bottom of the caliper bore to move the piston outward. This action slides the caliper inward, resulting in a clamping action on the brake rotor. This clamping act...

Removal

• Remove caliper assembly from steering knuckle as described in "Caliper Removal" under "Caliper Service."
• Remove inboard shoe. Dislodge outboard shoe and position caliper on front suspension so the brake hose will not support the weight of the caliper.
• Remove shoe support spring from piston.
• Remove two sleeves from inboard ears of caliper.
• Remove four rubber bushings from grooves in each of caliper ears.

Installation

• Lubricate new sleeves, rubber bushings, bushing grooves and mounting bolt ends with Delco Silicone Lube or its equivalent.
• Install new bushings and sleeves in caliper ...

Master Cylinder Overhaul

Except Aurora, Bonneville, Corvette, LeSabre, Park Avenue, Riviera, 88 & 98

Disassemble

Refer to Figs. and when performing the following procedures.

• Remove master cylinder from vehicle as follows:
• Disconnect and plug hydraulic lines.
• Remove two master cylinder attaching nuts, then the master cylinder.
• Remove reservoir cover and diaphragm. Discard old brake fluid in reservoir.
• Inspect cover and diaphragm. Replace if cut, cracked or deformed.
• Remove fluid level switch, if equipped.
• On models with compact master cylinder, remove proportioner valve assembly, Fig. ...

• Inspect components for damage and unusual wear. Replace as necessary.
• Inspect wheel cylinders. Boots which are torn, cut or heat damaged indicate need for wheel cylinder replacement.
• On type 1 brakes, remove wheel cylinder links. Fluid spill from boot center hole indicates cup leakage and need for wheel cylinder replacement.
• On type 2 brakes, use a small screwdriver to pry center hole of boot away from piston. If fluid spills from center hole, cup leakage is indicated and wheel cylinder should be replaced.
• On all types, light fluid coatings on piston within cylinder is considered normal.
• ...