Rear Disc Brake Hardware Replacement 1500 Series

Warning: Refer to Brake Dust Warning in the Preface section.

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



6. Compress the brake caliper pistons.

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

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

6.3.	Remove the C-clamp from the caliper.





Note: 

•	DO NOT use any air tools to remove or tighten the guide pin bolts. Use hand tools only.

•

Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolts. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brake is applied.

7. Using an open end wrench to hold the guide pins, loosen the guide pin bolts.



8. Remove the brake caliper guide pin bolts.

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.




9. Remove the caliper from the caliper bracket and support with heavy mechanics wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper.




Note: Mark the position of the brake pads for proper installation.

10. Remove the brake pads from the brake caliper bracket.
11. Remove the brake pad retaining springs.



12. Remove the guide pins (5) from brake caliper bracket (3).
13. Remove the guide pin boots (4) from the caliper bracket.

1. Lubricate the caliper bracket bushings and guide pins with high temperature silicone brake lubricant.
2. Install the guide pin boots (4) to the brake caliper bracket.
3. Install the guide pins (5) to the brake caliper bracket (3).



4. Install the brake pad retaining springs to the brake caliper bracket.

Note: If installing the original brake pads, position the brake pads in the location marked during removal.

5. Install the brake pads.



6. Install the brake caliper to the brake caliper bracket.



7. Install the brake caliper guide pin bolts.

Caution: Refer to Fastener Caution in the Preface section.





Note: 

•	DO NOT use any air tools to remove or tighten the guide pin bolts. Use hand tools only.

•

Install an open end wrench to hold the caliper guide pin in line with the brake caliper while removing or installing the caliper guide pin bolts. DO NOT allow the open end wrench to come in contact with the brake caliper. Allowing the open end wrench to come in contact with the brake caliper will cause a pulsation when the brake is applied.

8. Use an open end wrench to hold the caliper guide pin while tightening the guide pin bolt. Tighten the bolts to 38 N·m (28 lb ft).
9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
10. Lower the vehicle. Refer to Lifting and Jacking the Vehicle.
11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
12. Slowly release the brake pedal.
13. Wait 15 seconds, then repeat 11-12 until a firm pedal is obtained to properly seat the brake caliper pistons and pads.
14. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling.

Rear Disc Brake Hardware Replacement 2500 Series

Warning: Refer to Brake Dust Warning in the Preface section.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding.
4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
5. Compress the brake caliper pistons.

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

5.2.	Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.

5.3.	Remove the C-clamp from the caliper.




6. Remove the brake caliper bracket bolts.

Caution: Refer to Brake Caliper Caution in the Preface section.

Warning: 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.

7. Remove the caliper and caliper bracket as an assembly.
8. Remove the brake caliper bolts.
9. Remove the caliper from the caliper bracket.



10. Remove the brake pads from the caliper bracket.
11. Remove the anti-rattle clips.



12. Remove the slide pins (5) from the caliper bracket (3).
13. Remove the slide pin boots (4) from the caliper bracket.
14. Inspect the disc brake hardware. Refer to Rear Disc Brake Mounting and Hardware Inspection.

1. Lubricate the caliper bracket bushings and the slide pins with high temperature silicone brake lubricant.
2. Install the slide pin boots (4) to the caliper bracket.
3. Install the slide pins (5) to the caliper bracket (3).



4. Install the anti-rattle clips to the caliper bracket.
5. Install the brake pads.
6. Install the caliper to the caliper bracket.
7. Perform the following procedure before installing the caliper bracket bolts and the brake caliper bolts:

7.1.	Remove all traces of the original adhesive patch.

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

7.3.	Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.

8. Install the brake caliper bolts. DO NOT tighten.



9. Install the brake caliper bracket and caliper as an assembly.

Caution: Refer to Fastener Caution in the Preface section.

10. Install the brake caliper bracket bolts and tighten to 200 N·m (148 lb ft).
11. Tighten the brake caliper bolts to 108 N·m (80 lb ft).
12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
13. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
14. Slowly release the brake pedal.
15. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
16. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling.