1. Preparation:
* Safety First: Disconnect the negative battery terminal before starting any work on the braking system.
* Gather Tools and Parts: You'll need a socket set (metric), wrenches, a brake caliper rebuild kit (specific to your Corvette's caliper – ensure it's the correct kit!), a C-clamp or caliper compression tool, brake cleaner, grease (high-temp brake grease), and rags.
* Jack and Support: Safely jack up the Corvette and securely support it on jack stands. Never work under a vehicle supported only by a jack.
* Wheel Removal: Remove the wheels.
2. Caliper Removal:
* Disconnect Brake Line: Carefully loosen the brake line fitting at the caliper using a flare nut wrench. Have a container ready to catch any residual brake fluid. Be prepared for some fluid spillage. If possible, use a tubing wrench to avoid damaging the fitting.
* Disconnect Caliper Mounting Bolts: Locate and remove the bolts holding the caliper to the caliper bracket. These may be difficult to access depending on your caliper design.
* Remove Caliper: Carefully remove the caliper from the bracket. It may be stuck due to corrosion; use penetrating oil if needed.
3. Caliper Rebuild:
* Clean Thoroughly: Clean the caliper thoroughly using brake cleaner. Remove any old grease, dirt, or debris.
* Disassemble Caliper: Carefully disassemble the caliper according to your rebuild kit instructions. This typically involves removing the dust boots, piston seals, and any other worn components. Take pictures as you go to help with reassembly.
* Inspect Components: Carefully inspect all the components for wear or damage. Replace any worn or damaged parts with new components from your rebuild kit.
* Reassemble Caliper: Carefully reassemble the caliper, following the instructions in your rebuild kit. Pay close attention to the orientation of seals and dust boots.
* Lubricate: Apply a small amount of high-temperature brake grease to the specified locations as directed in your rebuild kit. Do not over-grease.
4. Caliper Reinstallation:
* Install Caliper on Bracket: Carefully install the rebuilt caliper onto the bracket.
* Connect Brake Line: Carefully reconnect the brake line to the caliper. Tighten the fitting to the manufacturer's specifications (check your repair manual).
* Attach Caliper to Bracket: Tighten the caliper mounting bolts to the manufacturer's specifications (check your repair manual).
* Compress Piston: Use a C-clamp or caliper compression tool to carefully compress the brake caliper piston. This will allow the brake pads to properly engage the rotor. Be careful not to damage the piston or seals.
* Install Wheel: Reinstall the wheel.
* Repeat for Other Side: Repeat the process for the other caliper on the same axle.
5. Bleed Brakes:
* After reassembling both calipers, you must bleed the brakes to remove any air that may have entered the system during the rebuild. Use a brake bleeder and a helper to properly bleed the system. Refer to your repair manual for proper bleeding procedures.
Important Considerations:
* Brake Fluid: Use the correct type of brake fluid specified for your Corvette.
* Torque Specifications: Always refer to your repair manual for the proper torque specifications for all bolts and fittings. Over-tightening can damage components.
* Professional Help: If you're uncomfortable performing this repair yourself, it's best to take your Corvette to a qualified mechanic. Brake systems are critical for safety.
This is a general guide only. Always consult your 1977 Corvette's repair manual for specific instructions and diagrams. Improperly rebuilt brakes can lead to serious accidents. If you are unsure about any step, seek professional help.
