GM 19331021
Caliper

Replacing the rear Brake Caliper Bracket begins with vehicle suspension and tire and wheel removal. Begin by removing the shield's nut and bolt then detach the quarter shaft shield from the vehicle. Secure the brake caliper in position using heavy mechanic's wire or equivalent material to prevent damage to the hydraulic flexible brake hose. Then remove the 2 brake caliper mounting bolts. Begin sequence by supporting the brake caliper while you remove its mounting bracket bolts and continue with disc brake pads and anti-rattle clips from the brake caliper mounting bracket. Add the brake caliper mounting bracket's anti-rattle clips and disc brake pads during installation. The 2 brake caliper mounting bracket bolts require preparation before installation. Begin by removing original adhesive then clean the threads with brake parts cleaner before applying threadlocker gm p/n 12345493 (Canadian P/N 10953488) to the threads. Mount the brake caliper mounting bracket then tighten the bolts to 200 nm (148 ft. Lbs.). Following cleaning operations on the 2 brake caliper mounting bolts, apply threadlocker gm p/n 12345493 (Canadian P/N 10953488) before bracket and caliper assembly where final bolt torque reaches 42 nm (31 ft. Lbs.). Replace the quarter shaft shield by tightening both hardware components to 25 nm (18 ft. Lbs.). To properly seat the brake caliper pistons and brake pads users must lower the vehicle after reassembly before gradually applying the Brake Pedal to 2/3 of its travel distance followed by slow pedal release of an amount necessary to achieve a steady Brake Pedal.

To install the new rear Brake Caliper Bracket start by lifting and securing the vehicle before removing the tire and wheel set up. Unbolt both parts of the quarter shaft shield before you can remove it. Install the brake caliper on mechanic's wire support and keep the hydraulic brake hose connected as you disconnect the two mounting bolts of the brake caliper. Loosen and support the brake caliper before removing both bolts from the caliper mounting bracket. Slide away the brake pads with their anti-rattle clips from the bracket. Install the brake caliper first by putting the anti-rattle clips and disc brake pads on the brake caliper mounting bracket. Clean the bolt threads with brake parts cleaner before applying threadlocker gm p/n 12345493 (Canadian P/N 10953488). Remove all original adhesive patch from these bolts. Mount the brake caliper on its base by tightening bolts to 148lb-ft torque. Follow the same process for the remaining 2 bolts and install the brake caliper in position before tightening them to 42 n.m (31 lb ft). Set the quarter shaft shield in place again and tight both metal fasteners to 25 n.m (18 lb ft). Realign the tire assembly then lower the vehicle. After switching off the engine apply the Brake Pedal halfway then release it slowly and repeat this several times to perfectly seat the brake pads and brake pistons.

The first step to replace a 2500 series brake caliper requires checking the brake master cylinder reservoir fluid level and then removing fluid to the midway point. Cautiously drain fluid while maintaining it at the point that separates maximum from minimum positions. First lift and stabilize the vehicle before taking off the tire and wheel assembly. To remove the caliper pistons first inspect the operation and use a c-clamp to press the pistons through the bore into the caliper. To prevent fluid loss from open brake pipe fittings you must first clean the brake hose end and then apply a cap to the exposed area. Carefully remove the brake hose to caliper bolt and brake hose followed by discarding two copper brake hose gaskets. Maintain the brake caliper mounting bolts tight but unset them while completely removing the bolts that fasten the mounting bracket. Primary damage to brakes occurs when you apply pressure to the pedal with rotors/calipers and drums detached. Uninstall the brake caliper and mounting bracket assembly while you separate the brake caliper from the bracket. The inspection of the caliper assembly leads to Brake Pad removal along with anti-rattle clips from the mounting bracket. Regularly inspect the mounting bracket for any cracks along with any signs of damage and replace both those and worn bushings when needed. A flat-bladed tool will help remove the old bushing before you install a new bushing by using a socket. To install this system begin by mounting brake pads and anti-rattle clips to the mounting bracket and then install the brake caliper. Use brake parts cleaner to clean the mounting bolts before applying threadlocker gm p/n 12345493 (Canadian P/N 10953488) and installing the bolts without applying torque. Complete brake caliper assembly with mounting bracket bolts reaching 300 nm (221 ft. Lbs.) torque then install caliper mounting bolts to 108 nm (80 ft. Lbs.). After removing the brake hose fitting rubber cap install two new copper brake hose gaskets and tighten the bolt to 40 nm (30 ft. Lbs.). Install the wheel tire assembly and lower the vehicle before pouring clean brake fluid into the master cylinder reservoir to its correct level. Following this, complete a hydraulic brake system bleed process.

Before replacing the front brake caliper you need to inspect the brake master cylinder reservoir. If fluid level exceeds the half-way mark between max and min indicators then drain fluid to reach that point. Lift the vehicle and start by taking out the tire and wheel unit. Press the brake caliper pistons into the caliper using a C-clamp across its top until all pistons fully retract. Put a rubber seal into the brake pipe exit while you need to clean up the hose fitting. Disassemble the brake hose from caliper bolt to retrieve 2 bonded copper gaskets that may be stuck on the caliper parts. Take out the brake caliper mounting bolts by removing the brake hose first then avoiding brake pedal depressions for safety reasons. Detach the brake caliper from its mounting position. Fitting the new brake caliper to its model bracket requires cleaning both surfaces thoroughly and refitting it with a dab of brake parts cleaner on the bolt threads. Before installing the 2 brake caliper mounting bolts apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to their threads and tightly torque them to 108 Nm (80 ft. lbs.). Insert two fresh copper brake hose gaskets into the brake caliper bolt opening before fastening the brake hose with 40 Nm (30 ft. lbs) torque. Open the brake system to remove air after installation then put back the wheel and tire assembly. Lower the vehicle and refill the master cylinder reservoir with fresh brake fluid.

To replace the rear Brake Caliper Bracket, initially, make sure safety by supporting the brake caliper with heavy mechanic's wire or the same type of the tool while the hydraulic flexible brake hose is connected to prevent the damages and potential leakage. You start by disassembling the caliper from the mounting bracket, using the hose, frames the brake pads and the anti-rattle clips from the Brake Caliper Bracket. Next, take off two Brake Caliper Bracket mounting bolts and the bracket itself, cleaning off the inside ends and the mounting surface of contaminants. To install, install the new Brake Caliper Bracket, removing all residue of the original adhesive patch, clean the bolt threads with denatured alcohol prior to installing threadlocker gm p/n 12345493 (Canadian P/N 10953488). Replace the two caliper bracket mounting bolts and tighten them to 200 nm (148 ft. Lbs.) and connect back the anti-rattle clips and brake pads, sliding the pads where they meet the rotor. Finally, install the brake caliper, tire, and wheel assembly, lower the vehicle and then slowly with the engine off pedal the brake pedal to about 2/3 of the pedal travel and release 2/3 travelled down repeat this procedure until a firm pedal is achieved making sure that the brake caliper pistons and pads seat properly.

To handle the 15 series rear brake caliper service you must first take it off the vehicle but protect the Piston during compressed air use by inserting wood instead of fingers. Push the Piston out while directing an airflow through the brake hose inlet fitting port, Piston boot, Piston seal, and brake caliper bleed screw cap in that order. Check the brake caliper's metal surface inside and seal area for rust damage. Replace the entire housing if the damage is severe. Also test the brake caliper holder mounting area for wear and replace it if the wear exceeds specifications. Use denatured alcohol to clean repair kit parts and other regions except brake pad guides. Then blow each surface dry with non-lubricated filtered compressed air to clear the brake caliper housing and bleeder valve. Put the brake caliper bleeder screw in place first before tightening it to 12 nm (106 inch lbs). After that, set the bleed screw cap. Apply brake fluid to the new Piston seal and seal groove of the caliper bore before placing them into position without twisting the seal. Push the brake Piston down into the bore while brake fluid coats both elements. Position the boot with folded part leading to Piston bore opening then press button into proper groove position. Afterward replace the brake caliper onto its original position.

When you overhaul the 25/35 series brake caliper at the back remove it from your vehicle but keep your fingers away from the Piston when pressing compressed air into it. Instead push the Piston back with a small stick as protection before beginning the repair. Use compressed air to blow out two pistons from the drain port of the brake hose then remove the Piston boots and seals. Check the brake system components for signs of excessive erosion or rust on both brake caliper bores and Piston seal grooves before changing the brake housing. Inspect the caliper mounting bracket for metal loss and replace it when the damage crosses accepted industry standards. Use denatured alcohol to wipe all parts clean followed by filtering non-lubricated compressed air into all brake caliper housing and bleeder valve spaces. After fitting the caliper bleed screw seal it to 12 nm using appropriate torque settings and finish with the bleed screw cap. Apply brake fluid to the new Piston seal and brake caliper bore seal groove while avoiding twisting the seal during installation. Apply lubricant to both brake caliper bore and Piston then attach the boot covering the Piston. Keep the boot fold aligned toward the brake caliper housing Piston bore and push the Piston into the bore when the boot fits snugly into the groove. Depress the Piston to its lowest position to let the boot take its proper position then repeat this step on all pistons before returning the brake caliper to its original position on the car.

Before replacing the 1500 series front brake caliper check master cylinder reservoir fluid level. If parallel with mid-point remove no fluid but if fluid is above the mid-point reduce it to that mark. Lift your vehicle with support stands before taking off the tire and wheel unit. Push brake caliper pistons back using 2 big c-clamps placed over the top of the unit towards the back of the outboard pad until they fully retract. Put on a rubber plug over the exposed brake pipe end to seal fluid loss before cleaning the area around the brake hose coupling. During brake hose removal discard the stuck copper gaskets which usually remain on the caliper and brake pipe ends before separating the components. After removing the brake caliper bolts you must handle the brake rotors-calipers properly when the brake pedals stay free for brake system protection. Put the new caliper on the caliper bracket and tighten bolt set to 100 nm (74 ft.lbs) torque. Install 2 new copper brake hose gaskets on the brake hose bolt and thread this assembly onto the brake hose before attaching it to the caliper bolt while tightening the bolt to 40 nm torque. After cleaning brake fluid from the hydraulic system you need to set the tire and wheel then top up brake reservoir to a suitable fluid level.

Begin replacements of the rear brake caliper by checking the fluid level inside the brake master cylinder reservoir. If the brake fluid mark stands at the midpoint between maximum and minimum range operators should not drain any fluid yet they must lower its amount if it surpasses this zone. After supporting the vehicle by raising it you need to disconnect the tire and wheel assembly. Use two large c-clamps to control the brake caliper pistons by placing them over the caliper housing top which engages the back surface of the outboard Brake Pad until the pistons achieve full retraction. After cleaning all contaminants from Brake Calipers and fittings install a cap or plug the brake hose to stop fluid from leaking out. Uninstall the brake hose to caliper bolt followed by the brake hose from the caliper without keeping or utilizing the copper gaskets. Replace the existing 2 copper brake hose gaskets with new ones during the installation process. Begin by removing the guide pin bolts from the brake caliper then detach the caliper from its mounting bracket. Use mounting bracket to install new brake caliper then torques brake caliper guide pin bolts to 108 nm (80 ft. Lbs.). The brake hose should have its cap or plug removed for fitment with 2 new copper brake hose gaskets before securing the brake hose to caliper bolt with a torque of 45 nm (33 ft. Lbs.). After bleeding the hydraulic brakes you must install the wheel assembly and top up the master cylinder with fresh brake fluid when necessary.

Check the brake master cylinder reservoir fluid level before brake caliper replacement. If the reservoir fluid is fully visible between minimum and maximum points, no fluid needs to be drained. Otherwise drain the reservoir fluid until it reaches halfway between maximum and minimum. Place the vehicle on jack stands and take out the tire together with the wheel assembly. Check the caliper performance before manually pushing the piston on top of the caliper housing with an extra-large c-clamp until the piston reaches maximum compression. After cleaning the hose end put a rubber cap or plug onto the brake pipe fitting to shield it from fluid losses and external contamination. Separate the brake hose from its caliper bolt using appropriate tools. Then disconnect the brake hose while getting rid of 2 copper gaskets for each brake hose. Keep the brake pedal up while pulling off the mount bolts from the brake caliper to prevent damaging parts. Examine the brake caliper components first then add the new brake caliper to the vehicle. Use a torque wrench to attach the brake caliper at 108 nm (80 ft. Lbs.) then take off the brake hose plug and replace the copper brake hose gaskets along with the inlet bolt using 45 nm (33 ft. Lbs.). Bleed your brake system hydraulic fluid then replace the tire and wheel. Take away safety stands and lift the vehicle. Complete with adding fresh brake fluid to the correct reservoir mark.

Service and repair of Brake Calipers require these specific tools: a Brake Caliper Piston boot seal installer represents tool number J 45515. Brake Caliper Piston boot seal installer (J 45515). The first step includes installing all brake caliper component parts along with the application of new Delco Supreme 11® solution GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid for improved assembly. Bleeding of the brake system needs to be performed whenever hydraulic system components get separated from their normal connection. Service operation must take place on this clean bench that provides a dry environment for providing torque values before you start working on non-lubricated fasteners. Detach the brake caliper from the automobile then drain all brake fluid. Apply compressed air with care to remove the piston but exercise safety measures to prevent injuries. When removing the piston, clean cloth pads should be used inside the caliper housing and a 25 mm block of wood should rest between the piston and caliper. Before inserting low-pressure compressed air into the brake caliper inlet hole, install a large C-clamp across the brake caliper body which assists piston extraction. Utilize denatured alcohol or equivalent liquid to cleanse the caliper piston bore and seal counterbore along with the caliper piston while averting abrasive substances. Check all brake caliper parts for damage and replace all damaged components. Apply Delco Supreme 11® brake fluid, GM P/N 12377967 (or Canadian P/N 10953488) or equivalent DOT-3 product to the new piston seal. Substitute the lubricated piston seals into the caliper bores. The Brake Caliper Piston boot seal installer (J 45515) enables precise installation of the dust boot seal during installation of the Brake Caliper Piston and new piston dust boot before reattachment to the vehicle.

You must begin by suspending the brake caliper with heavy mechanic's wire combined with the connection of the hydraulic flexible brake hose to avoid damage. Start by detaching the brake caliper from its bracket but leave the hose connected after which you can uninstall the brake pads and anti-rattle clips from the caliper bracket. You must remove the two Brake Caliper Bracket mounting bolts and the bracket components from the structure. Afterward clean any debris off the inside bracket ends while treating the mounting surface. Before applying the Brake Caliper Bracket mounting bolts position the bracket followed by removing all traces of original adhesive and cleaning bolt threads with denatured alcohol and applying threadlocker gm p/n 12345493 (Canadian P/N 10953488). The caliper bracket mounting bolts require a torque of 200 nm when installing jc5/jh5 system vehicles or 165 nm for jh6 systems. Brake systems using jc5/jh5 require 200 nm (148 ft. Lbs.) torque while jh6 systems need 165 nm (122 ft. Lbs.). For jh6 systems. Make sure to put the brake pads back in position while verifying they hit the rotor before fastening the bracket. For finishing the job replace the anti-rattle clips. Install the brake caliper while putting on the tire and wheel assembly then lower the vehicle until you slowly apply the Brake Pedal once to 2/3 its travel before letting it return to its original position. Apply each brake caliper with 200 nm torque utilizing a torque wrench before waiting 15 seconds for proper Brake Pad and caliper piston seating.

You must replace all repair kit contents before you start working on the front brake caliper and apply clean brake fluid to rubber parts for better handling. Repairing any hydraulic system items requires bleeding of the brake system after disconnecting them. It is important to put new brake pads into their matching axle set and tighten all ungreased fastener threads at their correct strength values. Complete maintenance steps on a sterile workspace that avoids mineral oil materials. For safe Piston removal direct compressed air into the brake hose inlet while holding the wood block in front of the Piston to protect it. Unscrew the brake caliper bleed screw cap and bleed screw before you take off the Piston boot, piston seal, and brake caliper boot. Replace the brake caliper housing as needed because the brake caliper bore and Piston seal groove have too much damage. When it comes to brake caliper mounting brackets always replace them when the guide surfaces show serious wear and corrosion. Remove all parts in the repair kit from brake caliper housing before wiping the parts to clean with alcohol and forcing filtered air through the hardware to eliminate all braking surfaces and flow channels. To build the system you should torque the bleed screw to 12 n.m (106 lb in) then attach its cap. Install the Piston seals into their respective grooves after rubbing brake fluid onto their surface stops and bore seal. Twist the seals carefully when placing them inside the brake caliper bores. Apply brake fluid to brake caliper bores and pistons before putting on their parts and boot. Ensure the boot fits well inside both the Piston groove and brake caliper bore groove. Rephrase the process for the opposite Piston before installing the brake caliper into its proper position.

Before replacing the front brake caliper of the 25/3500 series check the brake master cylinder fluid reservoir first. You need to drain the fluid when the reservoir shows a level higher than midway. After taking out the wheel and tire you must compress the brake caliper pistons with two c-clamps across the housing which pushes the pistons completely back into the caliper. Wipe the brake hose area clean before putting on a rubber plug to seal the exposed brake pipe. Take off the brake hose to caliper bolt and reject the 2 stuck brake hose copper gaskets before disconnecting the brake hose from the caliper. First disconnect the brake caliper bolts and watch for the pedal when removing rotors/calipers and drums to prevent brake damage. Connect the new caliper to its bracket and secure it through Brake Caliper Bolt tightening at 108 nm (80 ft. Lbs.). Place 2 new copper brake hose gaskets on the brake hose and caliper bolt before tightening the hose to caliper bolt to 40 nm (30 ft. Lbs.). Press brake fluid out of the hydraulic system then put back the wheel and tire while also adding enough brake fluid when needed.

Check the brake master cylinder reservoir before starting work. Replacing the front brake caliper does not affect fluid when the fluid is at the halfway mark. Lift the vehicle then detach the wheel and tire parts to start working. Press the caliper housing between the c-clamp and steel block until all brake pistons compress completely. Install protective caps at both ends to block fluid leaks before seizing the brake hose to bolt at the caliper unit. Dispose of the 2 copper brake hose gaskets after removing them from their stuck positions on the caliper housing or hose end before pulling off the brake hose. After removing brake caliper bolts stay away from pressing the brake pedal since braking components come off to protect them from harm. Take the brake caliper out from its securing bracket. Put the new brake caliper on its bracket first before applying brake washer cleaner to threads. Add threadlocker gm p/n 12345493 (Canadian P/N 10953488) and tighten 2 mounting bolts to 108 nm (80 ft. Lbs.). Replace the rubber cap of the brake hose fitting then install 2 copper brake hose gaskets. Attach the brake hose to caliper bolt and tighten it to 44 nm (32 ft. Lbs.). Empty the hydraulic brake system fluid then put back the wheel and tire parts and raise the vehicle before topping up the master cylinder with fresh brake fluid.

Begin replacements of the rear brake caliper by checking the fluid level inside the brake master cylinder reservoir. If the brake fluid mark stands at the midpoint between maximum and minimum range operators should not drain any fluid yet they must lower its amount if it surpasses this zone. After supporting the vehicle by raising it you need to disconnect the tire and wheel assembly. Use two large c-clamps to control the brake caliper pistons by placing them over the caliper housing top which engages the back surface of the outboard Brake Pad until the pistons achieve full retraction. After cleaning all contaminants from Brake Calipers and fittings install a cap or plug the brake hose to stop fluid from leaking out. Uninstall the brake hose to caliper bolt followed by the brake hose from the caliper without keeping or utilizing the copper gaskets. Replace the existing 2 copper brake hose gaskets with new ones during the installation process. Begin by removing the guide pin bolts from the brake caliper then detach the caliper from its mounting bracket. Use mounting bracket to install new brake caliper then torques brake caliper guide pin bolts to 108 nm (80 ft. Lbs.). The brake hose should have its cap or plug removed for fitment with 2 new copper brake hose gaskets before securing the brake hose to caliper bolt with a torque of 45 nm (33 ft. Lbs.). After bleeding the hydraulic brakes you must install the wheel assembly and top up the master cylinder with fresh brake fluid when necessary.

Before replacing the rear brake caliper check the brake master cylinder reservoir fluid level; no fluid needs to be drained when the fluid stands at the midway point between maximum and minimum marks but fluid should be drained if it sits higher than the midpoint. Lift the vehicle while setting it on supports before taking off the tire and wheel unit. Push the brake caliper pistons back by pressing the c-clamp down onto the top of the housing from the outside until the pistons are fully sealed inside. Put on a rubber cover to avoid brake fluid loss while cleaning the hose end. Disconnect the brake hose to caliper bolt to discard both copper brake hose gaskets. You must first disconnect the caliper guide bolt and detach the brake caliper from the assembly. Before fitting new brake pads compress the piston smoothly with a c-clamp through the caliper bores using an old Brake Pad or metal plate as protection. Lift and pull the inner edge of the caliper boots to remove air from their space and keep the boots lower than the top of the pistons. Place the brake caliper over the mounting bracket after discarding old adhesive and cleaning bolt threads with brake cleaner to put threadlocker gm part 12345493 (Canadian Part 10953488) on the bolt threads. Fit the brake caliper mounting bolts and tighten the guide pin bolts to 34 nm (25 ft. Lbs.) for 15 series models and 72 nm (53 ft. Lbs.) for 25/35 series models. Place a rubber cap aside from the brake hose fitting then put two new cupper brake hose gaskets onto the fitting receptacle before connecting the brake hose to caliper bolt. Tighten the bolt to 40 nm (30 ft. Lbs.). Release hydraulic pressure from the brake system then put back tire and wheel before placing the vehicle down and filling the reservoir with fresh brake fluid to required level.

You must replace all components from the repair kits then use clean brake fluid to lubricate the rubber parts for smooth assembly of the rear brake caliper system. Install your work on a bench which contains no mineral oil products and then take off the brake caliper. The hands should never contact the Piston directly during compressed air use for ensuring safety. Apply compressed air with a thin wooden piece to safely lead the air through the brake hose inlet fitting port to move the Piston. Start by removing the Piston boot alongside the Piston seal and after that extract the caliper bleed screw cap and caliper bleed screw. The caliper bore and Piston seal groove should be checked for unusual corrosion or scoring and the brake caliper needs replacement if these issues are detected alongside a caliper bracket guide surface wear inspection for necessary bracket replacement. Wipe down all unpainted parts and locations outside of the repair kit with denatured alcohol before clearing them with air compressed through a filtered unlubricated nozzle along with cleansing all minor openings in the caliper and bleeder valve. During assembly you should install the caliper bleed screw before tightening it to 12 nm (106 inch lbs.).fasten the caliper bleed screw cap afterwards. Apply brake fluid to new Piston seals and caliper bore seal grooves and carefully place them into their respective grooves without twisting them. Place the Piston into the bore while ensuring that the boot folds toward the brake caliper housing Piston bore opening before seating it within the brake caliper bore groove. Lower the Piston to its lowest position while making sure the boot occupies both the Piston groove and brake caliper bore groove before installing the brake caliper.

Starting the front brake caliper overhaul requires removing it from the vehicle first. First insert a small piece of wooden repair tool at the front of the Piston before directing compressed air into the brake hose inlet port in order to protect the components. After you remove the Piston boot and Piston seal you should proceed by taking off the brake caliper bleed screw cap and bleed screw. Residual brake fluid inside the brake caliper bore must show no signs of severe scoring, corrosion above normal wear levels. The brake caliper housing needs replacement when damage is detected. Replacement becomes necessary when corrosion or wear exists on the mounting bracket guide surfaces. Clean all residue from the brake pad guiding surfaces on the brake caliper housing and mounting bracket before using denatured alcohol to clean all repair kit-excluded parts. Use filtered non-lubricated compressed air to dry all parts and blow out all passages in the brake caliper housing and bleeder valve until clean. To assemble the brake caliper install the bleed screw and cap first and then apply brake fluid gm p/n 12388967 (Canadian P/N 992667) on new Piston seals and brake caliper bore seal grooves making sure the seals remain untwisted. First use brake fluid to lubricate the brake caliper bores and pistons before installing the boot and Piston with the correct seating in both Piston and bore grooves. Repetition of Piston lubrication and installation should occur before placing the brake caliper in its original position on the vehicle.

Start disassembly of the 1500 series w/nys and 25/3500 series rear brake caliper in a clean space without mineral oil materials while removing the brake caliper. Keep yourself safe when pushing out pistons with compressed air by inserting thin wood at the brake hose inlet fitting port before blowing air into it. Follow this process by first removing the Piston boots and seals then the caliper bleed screw together with its cap. Test the inside of brake caliper components for severe damage through erosion and rust. When this damage reaches unacceptable levels you will need a new caliper. If the caliper bracket guide surfaces show wear or rust damage you should replace it. Clean the caliper and bracket pad-supported surfaces properly while treating other parts with denatured alcohol and drying them with clean compressed air. When reassembling the caliper apply the bleed screw to 12 nm of torque then add the screw cap. Before inserting new seals apply enough brake fluid inside brake caliper bore seal grooves and Piston seals to prevent damage during the installation. Keep the seals in proper alignment as you put them in place. Apply brake fluid to both caliper bores and pistons before placing the boots onto the Piston ends with folds in position to enter the brake caliper housing. Push the boots into the grooves as you move pistons into their bores. Position the pistons to their bottom rests while making sure the boots seat correctly before putting the brake caliper in place.

To work on the rear brake caliper for 15 series vehicles start by taking out the component but keep fingers away from the Piston during compressed air use. Insert a thin wooden tool between the fitting port and Piston to shield the Piston during compressed air assists in brake hose removal. Remove both Piston boot and Piston seal before removing the brake caliper bleed screw and its cap. Examine the brake caliperbores and related seal groove for defects sent by wear and rust then replace the housing when serious problems exist. Look for damaged surfaces on the brake caliper mounting bracket. Replace it when needed. Disassemble the brake system parts. Clean all surfaces with denatured alcohol and dry them with filtered non-lubricated compressed air. Make sure all passages within the brake caliper and bleeder valve operate smoothly. After installation secure the brake caliper bleed screw to 12 nm (106 inch lbs.) then put on the bleed screw cap. Apply brake fluid to the new Piston seal and brake caliper bore seal groove before installation without twisting the seal during the process. Use brake fluid on the brake caliper bore and Piston before placing the boot on and making sure the fold points toward the Piston opening. Push the cylinder down through its bore groove until it reaches the bottom and keep the boot firmly positioned within the slot. Place the brake caliper unit in its proper position on the vehicle.

Start by assessing the brake master cylinder reservoir fluid level; if it stands around the mid-mark no fluid needs to be drained but if fluid is above this mark you must bring the liquid to the halfway point. Lift up the vehicle and take off the wheel and tire setup. Push brake caliper pistons firmly into position using a c-clamp on top of the housing against the back of the outboard pad. Insert a rubber plug over the brake pipe opening at its end to seal fluid while cleaning the brake hose for installation. Take the brake hose to caliper bolt loose and throw away its 2 copper brake hose gaskets since they may be stuck to caliper housing or hose end before detaching the brake hose from caliper. Take off the 2 brake caliper bolts while being careful not to push down on the brake pedal with the open brake system components. Detach the brake caliper from its mount. Position the brake caliper onto its mounting bracket and use 2 mounting bolts to fasten it before tightening to 108 nm (80 ft. Lbs.). Replace the rubber brake hose cap and attach the 2 new copper gaskets under it with the caliper bolt. Tighten the bolt to 40 nm (30 ft. Lbs.) when mounting it on the brake caliper. Drain the hydraulic brake system fluids before restating tire and wheel components down the vehicle then refill the brake tank to its correct fluid mark.

Replace all brake parts following the recommended kits and apply clean brake fluid on rubber components before making the assembly easier. Disconnecting any hydraulic part from the brake system may need bleeding. Change brake pads each time you replace the axle set and fasten dry lubricated components according to their correct torque values. Carry out all brake service tasks using a clean space that avoids mineral oil materials. Start by pulling off the brake caliper using caution to prevent fingers in front of the Piston as compressed air application could hurt you badly. Push the brake Piston back into the housing through a brake hose inlet port with compressed air while protecting it with wood. Tear the Piston boot off and remove the Piston seal along with the brake caliper bleed screw cap and bleed screw. Check the brake caliper's internal components for brake housing replacement when you find too much damage in brake caliper bores and Piston sealing groove. Examine the surfaces where the brake caliper mounting bracket attaches to find damage from oxidation and wear, then replace the bracket. Use denatured alcohol to clean all parts except repair kit contents and dry them with filtered compressed air. Also blow out all passageways and bleeder valve openings in the brake caliper housing. Before continuing establish the brake caliper bleed screw and tighten it to 12 nm (106 inch lbs.) afterward secure the bleed screw cap. Apply brake fluid to the new Piston seal and brake caliper bore seal groove before pressing it in place without twisting. Apply motor oil to brake caliper and Piston parts before putting the boot in place above the Piston. Keep the overfold facing the Piston bore entrance inside the brake caliper housing. Press the Piston into the brake caliper bore through the boot groove before pushing the Piston fully to the bottom groove while making sure it rests securely in both spaces. Reinstall the brake caliper onto your vehicle in the final step.

Before modifying the 25 series rear brake caliper you must put new elements from the repair kit into place and brush brake fluid across rubber components to enhance assembly. Perform all service steps on a clean area with no mineral oil present and apply the exact dry specific torque values. Take the brake caliper out of the vehicle first. The user should never put fingers near the Piston when applying compressed air to prevent hand injury. Place a thin wood piece in front of pistons to protect them before severing them through the brake hose inlet fitting port of the brake caliper housing. Discard the two pistons as well as both Piston boots and Piston seals before taking away the brake caliper bleed screw cap and bleed screw. Check the brake caliper bores and Piston seal grooves for wear and rust. Substitute the brake caliper housing when these parts reveal intense damage. Look for wear marks and rust on the brake caliper mounting bracket guide surfaces before replacing the bracket when needed. Use denatured alcohol to clean every component outside the repair kit before cleaning the brake pad guiding structures on both housings and brackets. Use non-lubricated filtered compressed air to clean all spaces in the brake caliper housing and bleeder valve. After installing the bleed screw insert torque settings of 12 nm into place then attach the bleed screw cap. Apply brake fluid to both the new Piston seal and brake caliper bore seal groove before seating the seal into its grooves without twisting it. Apply brake fluid to both the brake caliper bore and the Piston before placing them into position with the boot completely connected to each groove. Perform this installation process for all brake pistons. Reposition the brake caliper when the work is completed.

First check the fluid level inside the brake master cylinder reservoir on your 2500 series vehicle before starting the rear brake caliper replacement. You will not need to dispose of any fluid when the reservoir level sits at the midway point. Reduce the fluid to the midpoint if it exceeds that position. Separate the vehicle by raising and supporting it. After that remove the tire along with the wheel assembly. Advancing a c-clamp on top of the caliper body will force pistons towards caliper bores so you can remove the caliper. Protect the fluid in the brake system by applying a cap to the exposed brake pipe fitting while cleaning the brake hose end. The brake technicians need to detach the brake hose to caliper bolt and brake hose while getting rid of the two copper brake hose gaskets. Work on the brake caliper mounting bolts while leaving them in place before removing the caliper mounting bracket bolts. Do not activate the brake pedal after removing rotors/calipers or drums to protect the system. Disappear the caliper along with its bracket as a singular unit before extracting both bolts from the caliper followed by removal of the caliper from the bracket. Check the caliper assembly while removing brake pads and anti-rattle clips from the mounting bracket. An inspection of the mounting bracket for damage and cracks must be done while also replacing any damaged bushings encountered. You can replace the bushings by sliding a flat blade between the mounting bracket and bushing flange then rotating it to extract the bushing. Install the new bushing into the socket over the boot. The brake caliper installation requires fitting the anti-rattle clips and brake pads into the mounting bracket followed by installing the brake caliper. Apply gm p/n 12345493 threadlocker (Canadian P/N 10953488) on threads after cleaning them with brake parts cleaner before securing the mounting bolts. Place the brake caliper mounting bolts without torque before combining them with the brake caliper mounting bracket and caliper. Apply torque of 300 nm (221 ft. Lbs.) to all bolts securing the mounting bracket. Tighten the caliper mounting bolts to 108 nm (80 ft. Lbs.) while the brake caliper mounting bracket and caliper work as an assembly. Install the new brake hose gaskets on the brake fitting before tightening the bolt to 40 nm (30 ft-lbs) torque specification. Complete hydraulic brake bleeding while installing the tire-wheel assembly followed by vehicle lowering and finishing with master cylinder fluid up to the correct level using new brake fluid.

Bleed the hydraulic brake system, reinstall the tire and wheel assembly, and lower the vehicle.

Use compressed air directed into the brake hose inlet fitting port.

Inspect the fluid level in the brake master cylinder reservoir; if it is above the midway point between the maximum-full and minimum allowable levels, remove fluid to reach that point.

Lubricate the brake caliper bore and piston, install the boot over the piston with the fold facing the brake caliper housing, seat the boot into the groove, and slide the piston into the bore.

42 Nm (31 ft. lbs.).

Ensure all components from the repair kits are replaced and lubricate rubber parts with clean brake fluid for easier assembly.

Clean the brake hose end and install a rubber cap or plug.

Remove the rubber cap or plug from the brake hose fitting, install 2 NEW copper brake hose gaskets, and connect the brake hose by tightening the brake hose to caliper bolt to 40 N.m (30 lb ft).

The brake caliper bore and piston seal groove for excessive scoring or corrosion.

Clean all residue from the brake pad guiding surfaces on the brake caliper housing and mounting bracket.

Remove the brake hose to caliper bolt and discard the 2 copper brake hose gaskets.

Do not depress the brake pedal with the brake components removed to avoid damage.

Remove the rubber cap or plug from the brake hose fitting, install 2 new copper brake hose gaskets, and connect the brake hose by tightening the brake hose to caliper bolt to 40 Nm (30 ft. lbs.).

The piston boot and seal, followed by the brake caliper bleed screw cap and bleed screw.

Discard the 2 copper brake hose gaskets.

Remove the rubber cap or plug from the brake hose fitting, install 2 NEW copper brake hose gaskets, and tighten the brake hose to caliper bolt to 40 Nm (30 ft. lbs.).

Do not depress the brake pedal to avoid damage.

Use a flat-bladed tool to remove and a socket to install new bushings.

Inspect the brake caliper bore and piston seal groove for excessive scoring or corrosion.

Remove 2/3 of the brake fluid from the master cylinder.

Replace the brake caliper housing.

Inspect the caliper assembly, remove the brake pads and anti-rattle clips, and check the mounting bracket for cracks or damage, replacing it if necessary.

Replace the brake caliper housing.

Push the piston down to the bottom of the bore, ensuring the boot seats properly in both the piston groove and the brake caliper bore groove, and repeat for the remaining piston.

Remove the 2 brake caliper mounting bolts.

Lubricate the brake caliper bore and piston with brake fluid, then install the boot over the piston end with the fold facing the brake caliper housing piston bore opening.

Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid, ensuring the seal is not twisted before installing it.

First, remove the brake caliper from the vehicle.

Avoid depressing the brake pedal to prevent damage.

Ensure the boot is properly seated in both the piston groove and the brake caliper bore groove before finally installing the brake caliper back onto the vehicle.

Inspect the fluid level in the brake master cylinder reservoir.

Clean all residue from the brake pad guiding surfaces on the caliper and caliper bracket.

34 Nm (25 ft. lbs.) for the 15 Series or 72 Nm (53 ft. lbs.) for the 25/35 Series.

Clean all residue from the brake pad guiding surfaces and all parts not included in the repair kit with denatured alcohol, then dry them with filtered unlubricated compressed air and blow out all passages in the brake caliper housing and bleeder valve.

Remove the brake hose to caliper bolt and discard the 2 copper brake hose gaskets.

Slide the piston into the bore, pushing it down to the bottom and ensuring the boot seats properly.

Ensure safety by being aware of brake dust and brake fluid irritants.