Rear

Brake Caliper Replacement - Rear (All except 3500 Series)

Caution: Refer to Brake Dust Caution in Service Precautions.

Caution: Refer to Brake Fluid Irritant Caution in Service Precautions.

Removal Procedure
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 Vehicle Lifting.
5. Remove the tire and wheel assembly.





6. Compress the brake caliper piston or pistons.
^ 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 or pistons are pushed completely into the caliper bore or bores.
^ 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 housing or the brake hose end.





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





12. Remove the caliper guide pin bolts (25/35 series pickups).
13. Remove the brake caliper from the vehicle.
14. Inspect the caliper assembly.

Installation Procedure

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 to the caliper mounting bracket.
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 Threadlock GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.





5. Install the caliper guide pin bolts (15 series pickups).





6. Install the caliper guide pin bolts (25/35 series pickup).

Notice: Refer to Fastener Notice in Service Precautions.

7. Tighten the caliper guide pin bolts.
^ Tighten the caliper guide pin bolts to 42 Nm (31 lb ft) (15 series).
^ Tighten the caliper guide pin bolts to 108 Nm (80 lb ft) (25/35 series).





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

Important: Install 2 New copper brake hose gaskets.

9. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.
10. Connect the brake hose at the caliper by installing the brake hose to caliper bolt.
Tighten the bolt to 40 Nm (30 lb ft).
11. Bleed the hydraulic brake system.
12. Install the tire and wheel assembly.
13. Lower the vehicle.
14. Fill the master cylinder reservoir to the proper level with clean brake fluid.