Rebuilding the brake calipers on your 1982 Chevrolet Corvette can save you money. You can find brake caliper rebuild kits at most automotive parts suppliers. Follow recommended practice by changing the brake pads at the same time the calipers are rebuilt if the pads appear worn at all. The calipers must be resleeved if all of the imperfections cannot be removed by buffing the walls of the caliper bore. When the caliper bore walls are scratched and pitted, use the available and cost-effective option of rebuilt calipers.
Tools Used: Brake caliper rebuild kit, Jack, Jack stands, Lug wrench, Open end wrench set, Socket set, Pan to capture brake fluid, Small flat screwdriver, Soft hammer, Brake fluid
Rebuild the Brake Calipers
Park the car on a level surface. Raise the car with a hydraulic jack and position on jack stands for safety.
Remove the tire with a lug wrench and carefully remove the brake caliper with a socket wrench. Remove the banjo bolt that connects the brake line to the caliper with an open-end wrench and remove the brake line. Place the end of the line into a container to catch any brake fluid. Take off the retaining bolts that hold the caliper to the wheel with a socket wrench and remove the caliper from the car.
Separate the two halves of the caliper. Remove the brake pads by applying pressure to the butterfly clip and pushing the pad loose on each side. Take off the caliper dust boots using a flathead screwdriver, carefully prying upward. Remove the pistons, springs, and seals from the caliper with your fingers.
Clean the caliper with a lint-free cloth and brake cleaner. Check the caliper bores for scratching and scoring. Buff and polish any scratches with 600-grit emery cloth and wipe the surface clean.
Install new seals on the pistons by rubbing some brake fluid on them for lubrication. Slide the seal into the slot on the piston. Press the seal securely to the bottom of the groove. Hold the piston and spin the seal with your fingers to ensure the seal has been installed properly.
Rub some brake fluid on the sides of the caliper bore. Install the spring into the bore, followed by the piston. Position the piston level against the bore and gently work it into place. Work the piston seal into the bore using a small flathead screwdriver. Be careful not to scar any of the surfaces. Repeat the process on the other bores.
Install the outer dust seals over the pistons by pushing them in place with your fingers and tapping the edges with a small soft hammer until seated. Reassemble calipers and reinstall on the car. Repeat the process on the other three brakes.
Bleed each brake line, beginning with the rear brake furthest from the brake fluid reservoir. The brake fluid reservoir is located under the hood at the left rear side of the engine compartment. Open the reservoir cap and fill with new brake fluid. Position an box end wrench over the bleed screw and push a clear drain tube over it. Place the other end of the tube into a container to catch the excess fluid.
Open the bleed screw. Have a helper pump the brake pedal a few times until it becomes firm and then once more and hold. Release the bleeder screw a quarter of a turn and allow the fluid to drain. Close the drain screw just before the brake pedal is fully depressed. Repeat the process until the brake fluid drains continuously without any air bubbles. Check the brake fluid reservoir and add more fluid as needed. Repeat the process on the other three wheels. Remove the jack stands and lower the car.
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