Brake Caliper Replacement Front, Bendix

1. Apply the parking brake.
2. Block the wheels.
3. Tilt the cab. Refer to Cab Tilting in General Information.
4. Remove about 2/3 of the brake fluid from the master cylinder reservoir.

•	Do not completely drain the master cylinder reservoir.

•	Drain the fluid from the brake caliper bleeder valve.

•	Drain the fluid into a suitable container. Discard the fluid.

5. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle .
6. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation (Dual/Rear) in Tires and Wheels.



7. Remove the brake caliper retainer screw (1).
8. Remove the brake caliper retainer (3) and the brake caliper spring (2) using a brass punch.



9. Compress the pistons, using a C-clamp between the inner brake caliper housing and the outer brake pad.



10. If C-clamp is not available. Use screwdrivers in order to pry between the outer brake caliper housing and the outer brake pad.
11. While compressing the pistons, watch the reservoir for possible brake fluid overflow. The inner brake pad may stay on the brake caliper mounting plate (Bendix® Caliper).
12. Remove the two-bolts from the brake caliper.

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

13. Disconnect the brake hose from the brake calipers.
14. Cap or tape the brake hose fitting in order to prevent contamination.

Important: 

•	Clean the area around the brake hose on the brake caliper. Use Brake Parts cleaner GM P/N 12345754 or the equivalent.

•	Cap or tape the fitting in order to prevent dirt from entering the brake hose.

15. Remove the brake caliper.

Inspection Procedure

15.1.

Inspect the support rail surfaces on the brake caliper. For any deep nicks or gouges.

15.2.

Inspect the support rail surfaces on the brake caliper mounting plate. For any deep nicks or gouges.

15.3.

Inspect the V-way surfaces on the brake caliper and the support rail surfaces on the brake caliper mounting plate. For any deep nicks or gouges.

15.4.

Inspect the heat shields. If the heat shields are loose, replace the shields.

1. Clean the support rail surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the support rail surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.
3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or the equivalent, to the brake caliper mounting plate support rail surfaces.

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

4. Loosely assemble the brake hose nut to the brake caliper.

Tighten

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

•	Tighten the brake hose nut to 19 N·m (14 lb ft).

•	Tighten the brake hose bracket bolts to 32 N·m (24 lb ft).

5. Install the brake caliper.
6. Select a shim. Refer to Brake Caliper and Anchor Plate Wear Adjustment .
7. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper retainer and the brake caliper spring.



8. Tap the brake caliper retainer and brake caliper spring into place using a brass punch and a light weight hammer. The hose in the brake caliper retainer should line up with the threaded hole in the brake caliper mounting plate.

Important: The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

Important: Do not reuse the brake caliper retainer bolt .

Install NEW brake caliper retainer bolt (1).

Tighten
Tighten the brake caliper retainer bolt to 40 N·m (29 lb ft).

9. Lower the cab. Refer to Cab Tilting in General Information.
10. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 1052535, or the equivalent. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.

Caution: Do not move the vehicle until a firm brake pedal is obtained. Air in the brake system can cause the loss of brakes with possible personal injury.

11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

12. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
13. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation (Dual/Rear) in Tires and Wheels.
14. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
15. Remove the wheel blocks.

Brake Caliper Replacement Front, Dayton-Walther

1. Apply the parking brake.
2. Block the wheels.
3. Remove about 2/3 of the brake fluid from the master cylinder reservoir.

•	Do not completely drain the master cylinder reservoir.

•	Drain the fluid from the brake caliper bleeder valve.

•	Drained the fluid into a suitable container. Discard the fluid.

4. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Iformation.
5. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation (Dual/Rear) in Tires and Wheels.



6. Remove the brake caliper retainer bolt (1).
7. Remove the brake caliper retainer and brake caliper spring (2) using a brass punch.
8. Compress the pistons.



9. Use a C-clamp between the inner brake caliper housing and the outer brake pad.



10. If a C-clamp is not available. Use screwdrivers to pry between the outer brake caliper housing and the outer brake pad.
11. While compressing the pistons, watch the reservoir for possible brake fluid overflow.
12. Disconnect the brake hose.
13. Cap or tape the brake hose fitting in order to prevent contamination.

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

14. Remove the brake caliper.

1. Clean the area around the brake hose on the brake caliper. Use Brake Parts cleaner GM P/N 12345754 or the equivalent.
2. Inspect the V-way surfaces on the brake caliper. For any nicks or gouges.
3. Inspect the V-way surfaces on the brake caliper mounting plate.For any nicks or gouges.
4. Inspect the heat shields. If the heat shields are loose, replace the shields.

1. Clean the V-way surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the support rail surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.



3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or the equivalent, to the brake caliper mounting plate support rail surfaces.

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

4. Install the brake hose.

Loosely assemble the brake hose nut to the brake caliper.

Tighten

•

Refer to Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. in Caution and Notices.

•	Tighten the brake hose nut to 19 N·m (14 lb ft).

5. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969, or equivalent, to the brake caliper retainer and the brake caliper spring.



6. Tap the brake caliper retainer and brake caliper spring (2) into place using a brass punch and a light weight hammer. The hose in the brake caliper retainer should line up with the threaded hole in the brake caliper mounting plate (4).

Important: The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

Do not reuse the brake caliper retainer bolt .
Install NEW brake caliper retainer bolt.

Tighten
Tighten the brake caliper retainer bolt to 40 N·m (29 lb ft).

7. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 12377967 or the equivalent. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

9. Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
10. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation (Dual/Rear) in Tires and Wheels.
11. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Iformation.
12. Release the parking brake.
13. Remove the wheel blocks.

Brake Caliper Replacement Rear, Rail Slider

1. Block the wheels.
2. Apply the parking brake.
3. Tilt the cab. Refer to Cab Tilting in General Information.
4. Remove about 2/3 of the brake fluid from the master cylinder reservoir.

•	Do not completely drain the master cylinder reservoir.

•	Drain the fluid from the brake caliper bleeder valve.

•	Drain the fluid into a suitable container. Discard the fluid.

5. Raise the vehicle. Support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
6. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation (Dual/Rear) in Tires and Wheels.



7. Remove the brake caliper retainer screw (5).
8. Remove the brake caliper retainer (6) and the brake caliper spring (7) using a brass punch.



9. Compress the pistons. Using a C-clamp between the inner brake caliper housing and the outer brake pad.



10. If a C-clamp is not available. Use screwdrivers in order to pry between the outer brake caliper housing and the outer brake pad.
11. While compressing the pistons, watch the reservoir for possible brake fluid overflow. The inner brake pad may stay on the brake caliper mounting plate (Bendix® caliper).

Notice: Do not allow calipers to hang from the flexible hoses. Doing so can damage the hoses.

12. Disconnect the brake hose.

Important: 

•	Do not let the brake caliper hang from the brake hose. Suspend the brake caliper with a wire or cord.

•	Removing the brake hose from the brake caliper when replacing the brake pad assemblies is not always necessary.

•	Clean the area around the brake hose on the brake caliper.

•	Cap or tape the fitting in order to prevent dirt from entering the brake hose.

13. Remove the brake caliper.

Inspection Procedure

13.1.

Inspect the V-way surfaces on the brake caliper. For any nicks or gouges.

13.2.

Inspect the V-way surfaces on the brake caliper mounting plate. For any nicks or gouges.

13.3.

Inspect the dust shields. If the dust shields are loose, replace the shields.

1. Clean the V-way surfaces of the brake caliper with a wire brush. File smooth any deep nicks or gouges.
2. Clean the V-way surfaces of the brake caliper mounting plate with a wire brush. File smooth any deep nicks or gouges.



3. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969 or the equivalent, to the brake caliper mounting plate support rail surfaces.
4. Install the brake caliper.

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

5. Install the brake hose.
6. Loosely assemble the brake hose nut to the brake caliper.

Tighten

•

Refer to Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. in Caution and Notices.

•	Tighten the brake hose nut to 19 N·m (14 lb ft).

7. Install the brake caliper (5).
8. Install the brake caliper retainer spring (2) in the support rail.
9. Select an appropriate shim. Refer to Brake Caliper and Anchor Plate Wear Adjustment .
10. Apply a thin coat of Brake Caliper Lubricant GM P/N 12377969 or equivalent, to the brake caliper retainer and the brake caliper spring.



11. Tap the brake caliper retainer (3) and brake caliper spring into place using a brass punch and a light weight hammer. The hose in the brake caliper retainer should line up with the threaded hole in the brake caliper mounting plate.
12. Install the brake caliper retainer screw (1).

Important: The brake caliper retainer bolt boss must fit in the circular hole in the brake caliper retainer.

Do not reuse the brake caliper retainer bolt .
Install NEW brake caliper retainer bolt.

Tighten
Tighten the brake caliper retainer bolt to 40 N·m (29 lb ft).

13. Fill the master cylinder reservoir with brake fluid. Use Brake Fluid GM P/N 12377967 or the equivalent. Refer to Master Cylinder Reservoir Filling .
14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.

Important: Check the fluid level in the master cylinder reservoir after pumping the brake pedal.

Pump the brake pedal several times in order to ensure that the pedal is firm and the brake linings are adjusted.
15. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation (Dual/Rear) in Tires and Wheels.
16. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
17. Remove the wheel blocks.