Here's a general procedure. Specifics might vary slightly depending on the exact Cavalier model and trim. Always consult a repair manual specific to your year and model for detailed instructions and torque specifications.
Tools You'll Need:
* Jack and jack stands
* Wheel chocks
* Lug wrench
* Socket wrench and sockets (likely 13mm, 14mm, and possibly others)
* Caliper piston compression tool (C-clamp method can work, but a proper tool is safer and easier)
* Wire brush or brake cleaner
* Penetrating lubricant (PB Blaster or similar)
Procedure:
1. Safety First: Park on a level surface, engage the parking brake firmly, and chock the rear wheels. Use a jack to lift the front of the car and securely support it with jack stands. Never work under a car supported only by a jack.
2. Remove the Wheel: Loosen the lug nuts on the wheel you're working on before lifting the car. Once lifted, remove the lug nuts completely and take off the wheel.
3. Remove the Caliper: You'll need to remove the caliper to access the rotor.
* Locate the caliper bolts (usually 13mm or 14mm). Spray them with penetrating lubricant if needed.
* Unscrew the bolts and carefully remove the caliper. You may need to gently pry it away from the rotor.
* Important: Support the caliper with a bungee cord or wire to keep it from hanging by the brake line. This prevents strain on the brake line.
4. Compress the Caliper Piston: The caliper piston needs to be compressed to allow the caliper to slide back over the new, thicker rotor. Use a caliper piston compression tool for this. A C-clamp can work in a pinch, but the tool is better designed for this purpose and less likely to damage components. Be careful not to damage the piston seal or boot.
5. Remove the Rotor: The rotor should now be free to slide off the wheel hub. Sometimes they can be stubborn, so you may need to gently tap around the perimeter with a rubber mallet or a soft-faced hammer to break it loose. Avoid hitting the wheel studs.
6. Clean the Hub: Use a wire brush or brake cleaner to clean the wheel hub mating surface before installing a new rotor.
7. Install the New Rotor (if replacing): Slide the new rotor onto the wheel hub. Ensure it seats correctly.
8. Reinstall the Caliper: Make sure the caliper slides easily back into place. Reinstall the caliper bolts and tighten them to the manufacturer's specified torque.
9. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts. Lower the car to the ground and then fully tighten the lug nuts in a star pattern.
10. Check Brake Fluid Level: After reinstalling the caliper, check your brake fluid level in the master cylinder reservoir. If it's low, you may need to add brake fluid.
11. Test Drive: Once everything is put back together, test drive the vehicle to ensure the brakes are functioning properly.
Important Notes:
* If you're replacing the rotor, purchase a rotor specifically designed for your 2004 Chevy Cavalier.
* If the rotor is excessively rusted or worn, it may be difficult to remove. In this case, extra care and possibly some additional tools may be needed.
* If you're uncomfortable performing this repair yourself, take your vehicle to a qualified mechanic. Improper brake repair can be dangerous.
This is a general guide. Always refer to your vehicle's repair manual for detailed instructions and torque specifications. Failure to follow proper procedures could lead to brake failure, which is extremely dangerous.
