Tools You'll Need:
* Jack and jack stands: Crucial for safely lifting the car. Never work under a car supported only by a jack.
* Wheel chocks: To prevent the car from rolling.
* Lug wrench: To remove the wheel nuts.
* Sockets and wrenches: Appropriate sizes for your Cavalier's lug nuts and caliper bolts (likely metric).
* C-clamp or caliper compression tool: To compress the brake caliper piston.
* Hammer (optional, but helpful): For tapping things loose if needed.
* Penetrating oil (like PB Blaster): To help loosen rusty bolts.
* Torque wrench: Essential for tightening lug nuts and caliper bolts to the manufacturer's specifications (found in your owner's manual).
* Rotor removal tool (optional): May be needed if the rotor is stuck on the hub.
* Gloves and safety glasses: Always wear these for protection.
* Clean rags or shop towels: To clean up brake dust and fluid.
* New brake rotors: Make sure you get the correct ones for your year and model Cavalier.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the wheels.
2. Lift and Secure: Safely lift the car using the jack and secure it on jack stands.
3. Remove Wheel: Remove the lug nuts and take off the wheel.
4. Remove Caliper:
* Locate the caliper mounting bolts: These are usually on the back of the caliper.
* Apply penetrating oil if needed to help loosen the bolts.
* Remove the bolts: Keep track of their location and order if necessary.
* Carefully remove the caliper: You might need to gently pry it off the rotor. Support the caliper with a bungee cord or wire to keep it from hanging by the brake line. Avoid letting the brake line hang or get stressed.
5. Compress Caliper Piston: Use a C-clamp or caliper compression tool to push the piston back into the caliper. This creates space to remove the rotor. Be careful not to damage the piston seal. Some brake fluids are corrosive, so wear gloves.
6. Remove Rotor: The rotor should now be loose. Sometimes they can be stubborn. If it's stuck, gently tap it around the perimeter with a hammer, but be careful not to damage it. A rotor removal tool can also be helpful.
7. Clean the Hub: Clean the wheel hub thoroughly with a wire brush or suitable cleaner to ensure a good mating surface for the new rotor.
8. Install New Rotor: Slide the new rotor onto the wheel studs.
9. Reinstall Caliper: Carefully reinstall the caliper. Make sure it's correctly seated and attach the mounting bolts.
10. Tighten Bolts: Tighten the caliper bolts to the manufacturer's specified torque.
11. Reinstall Wheel: Replace the wheel and tighten the lug nuts in a star pattern to ensure even pressure. Tighten to the manufacturer's specified torque.
12. Lower Car: Carefully lower the car.
13. Torque Check: After driving a short distance, double-check that all bolts (lug nuts and caliper bolts) are still properly torqued.
Important Considerations:
* Brake Pads: Inspect your brake pads while you're at it. If they're worn, replace them. Doing both rotors and pads at the same time is often a good idea.
* ABS Sensors: Be careful not to damage the ABS sensor ring located on the wheel hub.
* Brake Fluid: If you're dealing with a significant amount of brake fluid, top off your master cylinder. Always check your fluid level.
* Bleeding Brakes: In some cases, especially after significant work on the brake system, you may need to bleed your brakes to remove air bubbles from the lines.
This guide provides general steps. Always refer to your vehicle's repair manual for specific instructions and torque specifications. The repair manual will provide details specific to your year and model Cavalier, which are critical for a successful and safe repair. Improper installation can lead to brake failure.
