Here's a general outline. Specifics may vary slightly depending on your Cavalier's trim level and options:
Tools You'll Need:
* Jack and jack stands (Crucial for safety)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric) with extensions and ratchets
* Torque wrench (essential for proper tightening)
* Caliper piston compressor tool (C-clamp can be used as a makeshift but less effective tool)
* Brake cleaner
* Wire brush or sandpaper
* New brake rotors (ensure they're the correct size for your Cavalier)
* New brake pads (highly recommended to replace these at the same time)
* Gloves
* Safety glasses
Procedure:
1. Safety First: Park your Cavalier on a level surface, engage the parking brake, and chock the rear wheels. Use jack stands to securely lift the vehicle. Never work under a car supported only by a jack.
2. Remove the Wheel: Loosen the lug nuts slightly with the lug wrench before jacking up the car. Once lifted, remove the lug nuts completely and carefully remove the wheel.
3. Remove the Caliper: Locate the caliper mounting bolts (usually two). Use the appropriate socket to unscrew them. The caliper may be slightly heavy, so support it as you remove the bolts to avoid stressing the brake line. You can often hang the caliper from the suspension using some wire or a bungee cord to keep it out of the way.
4. Compress the Caliper Piston: The caliper piston needs to be compressed to allow the new, thicker rotor to fit. Use a caliper piston compressor tool. Be careful not to damage the piston seal. Some pistons can be compressed by turning them with a flat head screwdriver in some designs (check your specific caliper design), but a dedicated tool is preferable.
5. Remove the Old Rotor: The old rotor may be held in place by a single or multiple screws or it may simply slide off. Inspect the rotor and hub for excessive rust or damage. Clean the hub thoroughly with a wire brush or sandpaper.
6. Install the New Rotor: Carefully slide the new rotor onto the wheel studs. If there are mounting screws, replace them with new ones, using the proper torque specification (consult your repair manual).
7. Reinstall the Caliper and Pads: Install the new brake pads (if replacing) into the caliper. Carefully slide the caliper back over the rotor and reattach the caliper mounting bolts, torquing them to the manufacturer's specifications.
8. Reinstall the Wheel: Replace the wheel and tighten the lug nuts in a star pattern (opposite nuts first) to ensure even pressure. Lower the car and fully tighten the lug nuts with the torque wrench.
9. Check for proper clearance: Make sure the brake rotor is not rubbing against the brake calipers or other components.
10. Pump the Brakes: Get back into your car and pump the brakes several times to ensure the brake pads and calipers are making proper contact with the rotors.
11. Test Drive: Take a short test drive to ensure the brakes are working correctly. Listen for any unusual noises.
Important Notes:
* Consult a repair manual specific to your 2003 Chevrolet Cavalier. This will provide detailed diagrams, torque specifications, and other crucial information.
* Brake work is dangerous. If you're uncomfortable with any part of this process, take your car to a professional mechanic.
* Always use the correct tools and follow safety procedures. Improperly installed brakes can lead to serious injury or death.
* Replace brake fluid if necessary. If you have to significantly bleed the brake system (if the brakes feel spongy after replacement), you may need to add new brake fluid. Never let the master cylinder run dry.
This is a general guide. The specifics of the process may vary depending on your vehicle. Always refer to your vehicle's repair manual for precise instructions and torque specifications. Remember safety is paramount!
