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mastershake · 06-15-2012, 05:57 PM

the creaking is the piston. you have to use kluber fluid around the seal. its a TSB.

Brake Noise/Creak During Slow Speed Braking (Lubricate Brake Caliper)
1999-2003 Chevrolet Malibu

2004 Chevrolet Malibu Classic

1999-2004 Oldsmobile Alero

1999-2004 Pontiac Grand Am

Condition
Some customers may comment on a creak type noise occurring when applying the brakes. It is usually heard only during slow speed brake maneuvers. If this condition exists, it should be able to be duplicated when the vehicle is not moving by depressing the brake and listening for the noise from the wheel-well/caliper area.

Cause
This condition may be caused by a caliper piston to seal interface issue during brake apply. If the caliper is removed and the piston is pushed back, the noise may be eliminated. This is usually only a temporary fix.

Correction
DO NOT REPLACE CALIPER.

To repair this condition, lubricate the entire circumference of the seal at the caliper piston interface using Kluber Fluid and the following procedure:

Remove the wheel and reinstall two lug nuts. This will hold the rotor to the bearing surface so debris does not fall between the surfaces and cause lateral runout (LRO).
Remove the bottom bolt from the caliper assembly without disturbing the hydraulic system.

Swing the caliper assembly up so the caliper assembly is facing upward.
Thoroughly clean the piston boot with GM approved Brake Clean. Pay particular attention to the area where the boot interfaces with the piston.
Using compressed air, dry the piston/boot area.

Remove the cap from the tip of the bottle and carefully insert the tip, P/N 89022161, between the boot and piston, inward of the piston boot groove.
From the top side of the piston (reference diagram), inject the lubricant. With the caliper in the tilted position, the lubricant will flow down and work its way around the entire circumference of the seal. Let the caliper body assembly remain in this position for a minimum of 2 minutes to allow for the fluid to completely work its way around the seal.
Push the piston into the seal to ensure the lubricant is on both the piston and seal surface.

Important
Excessive fluid could appear as a failure and lead to a comeback. To prevent unnecessary future repairs, it is important to only use one bottle per side and make sure excess fluid is wiped away.

Wipe away any excessive fluid.
Reassemble the caliper to the vehicle. Tighten
Tighten the caliper bolts to 31N·m(23 lb ft).

Repeat steps 1- 9 on the opposite side of the vehicle, if necessary.
Pump the brake pedal to push the caliper piston back into place.
Reinstall the wheel and test drive the vehicle to verify repair.

06-15-2012, 05:57 PM	#7
mastershake GL Member Join Date: Jan 2011 Location: michigan Posts: 414	the creaking is the piston. you have to use kluber fluid around the seal. its a TSB. Brake Noise/Creak During Slow Speed Braking (Lubricate Brake Caliper) 1999-2003 Chevrolet Malibu 2004 Chevrolet Malibu Classic 1999-2004 Oldsmobile Alero 1999-2004 Pontiac Grand Am Condition Some customers may comment on a creak type noise occurring when applying the brakes. It is usually heard only during slow speed brake maneuvers. If this condition exists, it should be able to be duplicated when the vehicle is not moving by depressing the brake and listening for the noise from the wheel-well/caliper area. Cause This condition may be caused by a caliper piston to seal interface issue during brake apply. If the caliper is removed and the piston is pushed back, the noise may be eliminated. This is usually only a temporary fix. Correction DO NOT REPLACE CALIPER. To repair this condition, lubricate the entire circumference of the seal at the caliper piston interface using Kluber Fluid and the following procedure: Remove the wheel and reinstall two lug nuts. This will hold the rotor to the bearing surface so debris does not fall between the surfaces and cause lateral runout (LRO). Remove the bottom bolt from the caliper assembly without disturbing the hydraulic system. Swing the caliper assembly up so the caliper assembly is facing upward. Thoroughly clean the piston boot with GM approved Brake Clean. Pay particular attention to the area where the boot interfaces with the piston. Using compressed air, dry the piston/boot area. Remove the cap from the tip of the bottle and carefully insert the tip, P/N 89022161, between the boot and piston, inward of the piston boot groove. From the top side of the piston (reference diagram), inject the lubricant. With the caliper in the tilted position, the lubricant will flow down and work its way around the entire circumference of the seal. Let the caliper body assembly remain in this position for a minimum of 2 minutes to allow for the fluid to completely work its way around the seal. Push the piston into the seal to ensure the lubricant is on both the piston and seal surface. Important Excessive fluid could appear as a failure and lead to a comeback. To prevent unnecessary future repairs, it is important to only use one bottle per side and make sure excess fluid is wiped away. Wipe away any excessive fluid. Reassemble the caliper to the vehicle. Tighten Tighten the caliper bolts to 31N·m(23 lb ft). Repeat steps 1- 9 on the opposite side of the vehicle, if necessary. Pump the brake pedal to push the caliper piston back into place. Reinstall the wheel and test drive the vehicle to verify repair. Last edited by mastershake : 06-15-2012 at 06:00 PM.