Rear Brake Caliper Replacement Exc. 35 Series

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum--full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



6. Compress the brake caliper piston.

•	Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.

•	Slowly tighten the C-clamp until the piston is pushed completely into the caliper bore.

•	Remove the C-clamp from the caliper.




7. Clean all dirt and foreign material from the brake hose end.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.

8. Remove the brake hose to caliper bolt from the brake caliper.
9. Remove the brake hose from the caliper.
10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.



11. Remove the caliper guide pin bolts (15 series pickups).



12. Remove the caliper guide pin bolts (15/25 series utilities, 25/35 series pickups).

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

13. Remove the brake caliper from the vehicle.
14. Inspect the caliper assembly. Refer to Brake Caliper Inspection .

Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads.

1. If you are installing new brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot.




Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air.

2. Ensure that the piston boot is below the level of the piston face.
3. Install the caliper.
4. Perform the following procedure before installing the caliper guide pin bolts (15 Series pickups only).

4.1.	Remove all traces of the original adhesive patch.

4.2.	Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.

4.3.	Apply Threadlocker GM P/N 12345493 or Red LOCTITE™ #272 to the threads of the bolt.




5. Install, but do not tighten the caliper guide pin bolts (15 series pickups).



6. Install, but do not tighten the caliper guide pin bolts (15/25 series utilities, 25/35 series pickup).

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.

7. Tighten the caliper guide pin bolts.

Tighten

•	Tighten the caliper guide pin bolts to 42 N·m (31 lb ft) (15 series).

•	Tighten the caliper guide pin bolts to 108 N·m (80 lb ft) (25 series).

8. Remove the rubber cap or plug from the exposed brake hose fitting end.

Important: Install NEW copper brake hose gaskets.

9. Assemble the NEW copper brake hose gaskets and the brake hose inlet fitting bolt to the brake hose.



10. Connect the brake hose at the caliper by installing the inlet fitting bolt.

Tighten
Tighten the inlet fitting bolt to 45 N·m (33 lb ft).

11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Antilock Brake System.
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
13. Remove the safety stands.
14. Lower the vehicle.
15. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.

Rear Brake Caliper Replacement 35 Series

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum--full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Inspect the caliper operation. Refer to Brake Caliper Inspection .



7. Compress the brake caliper piston.

•	Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.

•	Slowly tighten the C-clamp until the piston is pushed completely into the caliper bore.

•	Remove the C-clamp from the caliper.




8. Clean all dirt and foreign material from the brake hose end.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.

9. Remove the brake hose to caliper bolt from the brake caliper.
10. Remove the brake hose from the caliper.
11. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.



12. Remove the brake caliper mounting bracket bolts.

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

13. Remove the brake caliper and mounting bracket as an assembly.
14. Remove the brake caliper mounting bolts.
15. Remove the brake caliper from the mounting bracket.
16. Inspect the caliper assembly. Refer to Brake Caliper Inspection .



17. Remove the brake pads from the mounting bracket.
18. Remove the anti--rattle clips from the mounting bracket.
19. Inspect the mounting bracket for cracks and/or damage. Replace if necessary.
20. Inspect the mounting bracket bushings for damage and/or wear. Replace the bushings if necessary.
21. Perform the following procedure to replace the mounting bracket bushings.

•	Insert a flat bladed tool between the bushing flange and the mounting bracket.

•	Work the tool around the bushing flange and remove the bushing from the mounting bracket.

•	Place a socket over the boot onto the bushing flange and install the bushing to the mounting bracket.

1. Install the anti--rattle clips to the mounting bracket.
2. Install the brake pads to the mounting bracket.
3. Install the brake caliper to the mounting bracket.
4. Perform the following procedure before installing the caliper mounting bracket bolts and the caliper mounting bolts:

•	Remove all traces of the original adhesive patch.

•	Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.

•	Apply Threadlocker GM P/N 12345493 or Red LOCTITE™ #272 to the threads of the bolt.

5. Install the brake caliper mounting bolts. Do not tighten.



6. Install the mounting bracket and brake caliper as an assembly.

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.

7. Install the mounting bracket bolts.

Tighten
Tighten the mounting bracket bolts to 300 N·m (221 lb ft).

8. Tighten the brake caliper mounting bolts.

Tighten
Tighten the brake caliper mounting bolts to 108 N·m (80 lb ft).




9. Remove the rubber cap or plug from the exposed brake hose fitting end.

Important: Install NEW copper brake hose gaskets.

10. Assemble the NEW copper brake hose gaskets and the brake hose inlet fitting bolt to the brake hose.
11. Connect the brake hose at the caliper by installing the inlet fitting bolt.

Tighten
Tighten the inlet fitting bolt to 45 N·m (33 lb ft).

12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
14. Remove the safety stands.
15. Lower the vehicle.
16. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.