* Finding compatible calipers and rotors: You'll need to source calipers and rotors from a different vehicle model that's compatible with your Cavalier's rear axle and wheel mounting. There's no direct bolt-on solution. This requires significant research to find a donor vehicle with similar geometry and braking system that can be adapted.
* Fabricating or modifying brake lines: You'll need new brake lines routed to the new calipers. This likely means bending custom lines or adapting existing ones, requiring specialized tools and expertise.
* Modifying the backing plates or axle: The existing backing plates are designed for drums. You'll likely need to either significantly modify them or fabricate entirely new backing plates to accommodate the disc brake calipers. The axle itself might also require modification or replacement, depending on the donor parts you choose.
* E-brake modification: The existing emergency brake system is designed for drum brakes. You'll need to either integrate a cable-operated disc brake system or find a hydraulic e-brake solution and completely overhaul the system.
* Wheel compatibility: You may need different wheels to accommodate the larger calipers and rotors.
* Proper proportioning valve adjustment (critical): The proportioning valve in your braking system distributes braking force between the front and rear brakes. With the rear brakes going from drums to discs, the braking force distribution will change drastically, potentially causing the rear brakes to lock up easily. You'll need to adjust this valve (or potentially replace it) for safe and balanced braking. Getting this wrong is dangerous.
* Bleeding the brakes: After installation, you'll need to properly bleed the entire braking system to remove any air from the lines.
In short: This is a major mechanical project that requires significant expertise, specialized tools, and a deep understanding of automotive braking systems. It's not a job for someone without substantial mechanical experience. Attempting this without the proper knowledge and skills could lead to a dangerous and unreliable braking system.
Instead of attempting this conversion, consider:
* Upgrading the existing drum brakes: This is a much simpler and safer option. New shoes, cylinders, and hardware will significantly improve stopping power.
* Accepting the limitations: Drum brakes are perfectly adequate for many driving situations, especially in a car as light as a Cavalier.
If you're serious about upgrading your braking system, it's strongly recommended to seek the assistance of a qualified and experienced automotive mechanic. This project is far more complex and potentially dangerous than it might initially seem.
