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I have done my research and did the complete 4 wheel switch. I made up this document as a help document to aide those who are looking to convert. I can send it to whoever wants it. Just email fedwik@hotmail.com. Hope it helps:
2008-2010 Cobalt SS Brake Conversion on a 2006 Pontiac G6 GTP
Front Installation Notes:
The biggest issue with the Brembos on a G6 is making sure they clear the rims. I know some G6 inch rims clear but I have no idea what ones. The factory 18 inch GTP rims do not clear as the caliper sticks out 0.7mm further than the back side of the spokes. A 3mm spacer is required although I know some people use 5mm spacers. With 5mm spacers you only get about 3 threads vs. 7 for stock wheels from what I can tell. The 1/8” or 3mm spacers should get you 5 threads which are 98% of the stud holding capacity I have been told, so it should be OK. It also gives you 2.5 mm space between the caliper and the wheel. Also with 3mm spacers, you get about 1mm of hub to wheel contact for centering which should be adequate.
Stock front brake lines work just fine, no change required. If switching to stainless steel brake lines, you may lose the front brake line bracket. It can be swapped over, but I noticed with wheel travel and turning, the bend radius can get pretty sharp with the stock bracket being used.
*Note: See Brake Line Section for Details About Front Brake Lines if Using Stainless Steel Brake Lines.
The stock G6 caliper retaining bolts work just fine with the Brembo calipers for bolting to the spindle. No change is needed. Also note that when installing the pads and pins for the Brembo calipers, you need to install the pins from the inside holes on the back side of the caliper outwards with the split retainer “ball” on the end of the pin towards the center of the car. The pointy end of the pin should point outwards. You will need to use a brass drift and a hammer to gently seat the pins until the “ball” snaps into a recessed hole in the caliper. The back of the pin will now be flush with the caliper body. This way the pins are fully retained.
Front Conversion Parts:
Front Conversion Parts List: - All GM PN’s given – Can source through aftermarket as I have a lot of luck with Rock Auto (www.rockauto.com) or EBay
* Left Brembo caliper - 25900763
* Right Brembo caliper - 25900764
* Front Caliper Guide Pin Kit – 25900781 - *Note: 2 sets required
* Front Rotor – 15893541 - *Note: 2 sets required
* Front Pad Kit – 25808929
Rear Installation Notes:
The rear is also a bolt on but requires more stuff to bolt on. You will need to either modify or remove the rear dust shields which are held in place between the wheel hub assembly and the aluminum spindle. Aside from the calipers, rotors, and pads, you would need the stock rear brake lines modified or go with custom stainless steel braided lines. The Cobalt SS rear brake lines are too short to be utilized as they are only 8.5” long.
If you are buying new calipers, remember they DO NOT come with the caliper brackets. This is a crucial watch-out and 2 are required for installation. They are only available from GM as they only were sold for the 2008-10 Cobalt SS’s so the aftermarket does not support them. I strongly recommend Crate Engine Depot (www.crateenginedepot.com) for procuring these or any of the other required GM parts.
*Note: See Brake Line Section for Details About Front Brake Lines if Using Stainless Steel Brake Lines.
Also, the e-brake setup is different, but everything swaps over just fine.
Rear Conversion Parts:
Rear Conversion Parts List: - All GM PN’s given – Can source through aftermarket as I have a lot of luck with Rock Auto (www.rockauto.com) or EBay
* Left Caliper: 25902073 - *Note: 2008 Solstice GXP rear pads will fit
* Right Caliper: 25902074 - *Note: 2008 Solstice GXP rear pads will fit
* Caliper Bracket: 25869424 - *Note: You must get this through GM dealer – No aftermarket support – Only used on 2008-2010 Cobalt SS – Will work for either side – 2 required.
* Caliper Guide Pins: - 18034477 - *Note: 2 sets required
* Rear Rotor: 15921402 - *Note: 2 sets required
* Left Brake Line: 22720042 - Option to go to stainless steel braided lines – Note: SS calipers require a 12mm x 1.0 banjo bolts. Stock G6 rear calipers use 10mm banjo bolts. – Stock lines can have the end drilled out to ½” or 13mm and filed the end to fit.
* Right Brake Line: 22720042 - Option to go to stainless steel braided lines – Note: SS calipers require a 12mm x 1.0 banjo bolts. Stock G6 rear calipers use 10mm banjo bolts. – Stock lines can have the end drilled out to ½” or 13mm and filed the end to fit.
*Note: If buying new calipers, you will need 2 new 12mm x 1.0 banjo bolts. They DO NOT come with the calipers.
Brake Line Installation & Parts Notes:
Remember this is because of the difference in the banjo bolt size for the rear caliper. You could also just buy the bigger banjo bolt and drill the stock lines out to ½” or 13mm and file the end of the banjo fitting to fit the recess in the caliper. The front stock brake lines work just fine, so no change is needed.
The stock lines for the G6 are the following specs:
Front – 15” Long with 10mm Banjo (straight, no bend) and a 10mm x 1.0 inverted female flare.
Rear – 13.75” Long with 12mm Banjo (30-45 degree bend) and a 10mm 1.0 inverted female flare.
*Note: 2008-2010 Cobalt SS rear brake lines are 8.5” long and too short to be used on the G6.
This is why I chose to get 14” long lines. You can also go ahead and get 16” long line and give yourself a little extra length.
You can get a kit made from BMD Performance (www.bmdperformance.com) or make them up utilizing the following components from Summit Racing (www.summitracing.com) or similar:
* Russell Performance – R4058C – 12mm Banjo w/ 35 degree – 3AN Male – 2 required – In question Will verify and update with new PN.
* Fragola Performance Systems – 650202 – 10mm x 1.0 Inverted Flare Female – 3AN Male – 4 required
* Russell Performance – R4047C – 10 mm Banjo Straight – 3AN Male – 2 required
* Summit Racing – SUM-220303 – 14” Braided SS Brake Line – 3AN Female – 4 required
If you purchase them from BMD Performance, make sure you tell them you are converting all four wheels to the Cobalt SS brakes so they get the right banjo fittings installed in the rear.
*Note: With the Summit Racing line setup, the stock frame brackets for holding the stationary end of each flexible line will need to be enlarged one step to 5/8” (.625”) to allow the fitting to slide up high enough to use an ordinary brake line retaining clip that look like a horse shoe.
Cory
I have done my research and did the complete 4 wheel switch. I made up this document as a help document to aide those who are looking to convert. I can send it to whoever wants it. Just email fedwik@hotmail.com. Hope it helps:
2008-2010 Cobalt SS Brake Conversion on a 2006 Pontiac G6 GTP
Front Installation Notes:
The biggest issue with the Brembos on a G6 is making sure they clear the rims. I know some G6 inch rims clear but I have no idea what ones. The factory 18 inch GTP rims do not clear as the caliper sticks out 0.7mm further than the back side of the spokes. A 3mm spacer is required although I know some people use 5mm spacers. With 5mm spacers you only get about 3 threads vs. 7 for stock wheels from what I can tell. The 1/8” or 3mm spacers should get you 5 threads which are 98% of the stud holding capacity I have been told, so it should be OK. It also gives you 2.5 mm space between the caliper and the wheel. Also with 3mm spacers, you get about 1mm of hub to wheel contact for centering which should be adequate.
Stock front brake lines work just fine, no change required. If switching to stainless steel brake lines, you may lose the front brake line bracket. It can be swapped over, but I noticed with wheel travel and turning, the bend radius can get pretty sharp with the stock bracket being used.
*Note: See Brake Line Section for Details About Front Brake Lines if Using Stainless Steel Brake Lines.
The stock G6 caliper retaining bolts work just fine with the Brembo calipers for bolting to the spindle. No change is needed. Also note that when installing the pads and pins for the Brembo calipers, you need to install the pins from the inside holes on the back side of the caliper outwards with the split retainer “ball” on the end of the pin towards the center of the car. The pointy end of the pin should point outwards. You will need to use a brass drift and a hammer to gently seat the pins until the “ball” snaps into a recessed hole in the caliper. The back of the pin will now be flush with the caliper body. This way the pins are fully retained.
Front Conversion Parts:
Front Conversion Parts List: - All GM PN’s given – Can source through aftermarket as I have a lot of luck with Rock Auto (www.rockauto.com) or EBay
* Left Brembo caliper - 25900763
* Right Brembo caliper - 25900764
* Front Caliper Guide Pin Kit – 25900781 - *Note: 2 sets required
* Front Rotor – 15893541 - *Note: 2 sets required
* Front Pad Kit – 25808929
Rear Installation Notes:
The rear is also a bolt on but requires more stuff to bolt on. You will need to either modify or remove the rear dust shields which are held in place between the wheel hub assembly and the aluminum spindle. Aside from the calipers, rotors, and pads, you would need the stock rear brake lines modified or go with custom stainless steel braided lines. The Cobalt SS rear brake lines are too short to be utilized as they are only 8.5” long.
If you are buying new calipers, remember they DO NOT come with the caliper brackets. This is a crucial watch-out and 2 are required for installation. They are only available from GM as they only were sold for the 2008-10 Cobalt SS’s so the aftermarket does not support them. I strongly recommend Crate Engine Depot (www.crateenginedepot.com) for procuring these or any of the other required GM parts.
*Note: See Brake Line Section for Details About Front Brake Lines if Using Stainless Steel Brake Lines.
Also, the e-brake setup is different, but everything swaps over just fine.
Rear Conversion Parts:
Rear Conversion Parts List: - All GM PN’s given – Can source through aftermarket as I have a lot of luck with Rock Auto (www.rockauto.com) or EBay
* Left Caliper: 25902073 - *Note: 2008 Solstice GXP rear pads will fit
* Right Caliper: 25902074 - *Note: 2008 Solstice GXP rear pads will fit
* Caliper Bracket: 25869424 - *Note: You must get this through GM dealer – No aftermarket support – Only used on 2008-2010 Cobalt SS – Will work for either side – 2 required.
* Caliper Guide Pins: - 18034477 - *Note: 2 sets required
* Rear Rotor: 15921402 - *Note: 2 sets required
* Left Brake Line: 22720042 - Option to go to stainless steel braided lines – Note: SS calipers require a 12mm x 1.0 banjo bolts. Stock G6 rear calipers use 10mm banjo bolts. – Stock lines can have the end drilled out to ½” or 13mm and filed the end to fit.
* Right Brake Line: 22720042 - Option to go to stainless steel braided lines – Note: SS calipers require a 12mm x 1.0 banjo bolts. Stock G6 rear calipers use 10mm banjo bolts. – Stock lines can have the end drilled out to ½” or 13mm and filed the end to fit.
*Note: If buying new calipers, you will need 2 new 12mm x 1.0 banjo bolts. They DO NOT come with the calipers.
Brake Line Installation & Parts Notes:
Remember this is because of the difference in the banjo bolt size for the rear caliper. You could also just buy the bigger banjo bolt and drill the stock lines out to ½” or 13mm and file the end of the banjo fitting to fit the recess in the caliper. The front stock brake lines work just fine, so no change is needed.
The stock lines for the G6 are the following specs:
Front – 15” Long with 10mm Banjo (straight, no bend) and a 10mm x 1.0 inverted female flare.
Rear – 13.75” Long with 12mm Banjo (30-45 degree bend) and a 10mm 1.0 inverted female flare.
*Note: 2008-2010 Cobalt SS rear brake lines are 8.5” long and too short to be used on the G6.
This is why I chose to get 14” long lines. You can also go ahead and get 16” long line and give yourself a little extra length.
You can get a kit made from BMD Performance (www.bmdperformance.com) or make them up utilizing the following components from Summit Racing (www.summitracing.com) or similar:
* Russell Performance – R4058C – 12mm Banjo w/ 35 degree – 3AN Male – 2 required – In question Will verify and update with new PN.
* Fragola Performance Systems – 650202 – 10mm x 1.0 Inverted Flare Female – 3AN Male – 4 required
* Russell Performance – R4047C – 10 mm Banjo Straight – 3AN Male – 2 required
* Summit Racing – SUM-220303 – 14” Braided SS Brake Line – 3AN Female – 4 required
If you purchase them from BMD Performance, make sure you tell them you are converting all four wheels to the Cobalt SS brakes so they get the right banjo fittings installed in the rear.
*Note: With the Summit Racing line setup, the stock frame brackets for holding the stationary end of each flexible line will need to be enlarged one step to 5/8” (.625”) to allow the fitting to slide up high enough to use an ordinary brake line retaining clip that look like a horse shoe.
Cory
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