Brake Caliper Replacement - Rear (1500 Series)
Removal Procedure
Caution: Use Brake Dust Caution!
Caution: Use Brake Fluid Irritant Caution!
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 then 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 then 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.
[2500 shown, 1500 similar)
6. Compress the brake caliper 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 pistons are pushed completely into the caliper 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 and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
10. Remove the caliper guide pin bolts.
11. Remove the brake caliper from the vehicle.
12. Inspect the caliper assembly. Refer to Brake Caliper Inspection .
Installation Procedure
Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new brake pads.
1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots.
Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both pistons to release any trapped air.
2. Ensure that the caliper boots are below the level of the face of both pistons.
3. Install the brake caliper to the brake caliper mounting bracket.
4. Perform the following procedure before installing the caliper guide pin bolts.
1. Remove all traces of the original adhesive patch.
2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 1095348
to the threads of the bolt.
5. Install the brake caliper mounting bolts.
Notice: Refer to Fastener Notice in Cautions and Notices.
6. Tighten the brake caliper guide pin bolts.
Tighten
Tighten the bolts to 42 N?m (31 lb ft).
7. Remove the rubber cap or plug from the exposed brake hose fitting end.
Important: Install 2 New copper brake hose gaskets.
8. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.
9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt.
Tighten
Tighten the brake hose to caliper bolt to 40 N?m (30 lb ft).
10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Antilock Brake System.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Lower the vehicle.
13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
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Removal Procedure
Caution: Use Brake Dust Caution!
Caution: Use Brake Fluid Irritant Caution!
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 then 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 then 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.
[2500 shown, 1500 similar)
6. Compress the brake caliper 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 pistons are pushed completely into the caliper 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 and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
10. Remove the caliper guide pin bolts.
11. Remove the brake caliper from the vehicle.
12. Inspect the caliper assembly. Refer to Brake Caliper Inspection .
Installation Procedure
Important: Use denatured alcohol to clean the outside surface of caliper boots before installing new brake pads.
1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots.
Important: Use a small flat-bladed tool and lift the inner edge of the caliper boots next to both pistons to release any trapped air.
2. Ensure that the caliper boots are below the level of the face of both pistons.
3. Install the brake caliper to the brake caliper mounting bracket.
4. Perform the following procedure before installing the caliper guide pin bolts.
1. Remove all traces of the original adhesive patch.
2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 1095348
to the threads of the bolt.
5. Install the brake caliper mounting bolts.
Notice: Refer to Fastener Notice in Cautions and Notices.
6. Tighten the brake caliper guide pin bolts.
Tighten
Tighten the bolts to 42 N?m (31 lb ft).
7. Remove the rubber cap or plug from the exposed brake hose fitting end.
Important: Install 2 New copper brake hose gaskets.
8. Assemble the 2 New copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.
9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt.
Tighten
Tighten the brake hose to caliper bolt to 40 N?m (30 lb ft).
10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Antilock Brake System.
11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Lower the vehicle.
13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
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