1. Safety First:
* Wear safety glasses: Brake fluid can spray.
* Use gloves: Brake fluid is corrosive.
* Vehicle on a level surface and secure: Engage the parking brake firmly.
* Wheel chocks: Place wheel chocks behind the wheels that *aren't* being worked on.
2. Tools You'll Need:
* C-clamp or caliper piston compressor tool: A dedicated tool is best, but a C-clamp can work in a pinch. Avoid using screwdrivers or other improvised tools, as they can damage the piston.
* Wrench(es): To remove the caliper mounting bolts.
* Socket(s) or wrench: May be needed to remove the caliper guide pins or bolts. (Sometimes these require a Torx bit)
* Clean rags or shop towels: To clean up brake fluid spills.
* Brake cleaner: To clean the caliper and piston.
3. Procedure:
* Remove the wheel: Use the lug wrench to remove the wheel nuts and take off the wheel.
* Remove the caliper: Locate the caliper mounting bolts (usually two) and carefully remove them. Support the caliper with your hand or a bungee cord to prevent it from dangling by the brake line. Some calipers have slide pins that need to be removed and lubricated before removing the caliper.
* Inspect the caliper and guide pins: Check for damage, corrosion or wear. Lubricate the slide pins with caliper grease.
* Push back the piston: This is the crucial step. Never simply push the piston back with a screwdriver or other sharp object; you'll almost certainly damage the piston seal.
* Using a C-clamp: Carefully position the C-clamp jaws against the piston. Slowly and steadily apply pressure. The piston should retract smoothly.
* Using a caliper piston compression tool: These tools are specifically designed to fit various caliper pistons and apply even pressure, minimizing the risk of damage. Follow the manufacturer's instructions.
* Important Note on ABS: Some systems (like ABS) may require you to turn the ignition on and off repeatedly while pushing the piston to allow it to retract. This is due to the electronic pressure regulator located near the ABS pump and may not always be necessary. Consult your repair manual if unsure.
* Slowly and steadily: Apply even pressure. If you meet resistance, stop and investigate. There might be air in the system. Don't force it.
* Watch for brake fluid: As the piston retracts, brake fluid will be pushed back into the reservoir. Make sure the reservoir isn't overflowing. If it is, remove some fluid to prevent spills.
* Install new pads: Install the new brake pads, ensuring they are properly seated.
* Reinstall the caliper: Carefully bolt the caliper back onto the caliper bracket.
* Reinstall the wheel: Tighten the lug nuts according to the manufacturer's specifications.
* Pump the brakes: Several times to ensure the new pads are making contact with the rotor.
* Check brake fluid level: Top off the brake fluid reservoir if necessary.
* Test drive: Test the brakes carefully before driving normally.
4. Important Considerations:
* Consult a repair manual: A repair manual specific to your 2004 Chevy Malibu will provide detailed instructions and diagrams. This is highly recommended.
* If you are uncomfortable: If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Brake system repair is crucial for safety.
Remember, safety is paramount when working on your brakes. If you are unsure about any step, consult a professional. Improper brake repair can lead to dangerous situations.
