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Home >> Chevrolet >> 2002 >> C3500 HD 8.1 G, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1688 (Disc Brakes (Except Cab & Chassis, & Hd)) >> Repair Instructions >> Rear Brake Caliper Overhaul (25/35 Series) >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra and 2002 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Exploded View Of Brake Caliper Components
GM369865
IMPORTANT:
  • Replace all the components included in the repair kits used to service this brake caliper
  • Lubricate the rubber parts with clean brake fluid to make assembly easier
  • The torque values specified are for dry, non lubricated fasteners
  • Perform the service operations on a clean bench free from all mineral oil materials
  1. Remove the brake caliper from the vehicle. Refer to Rear Brake Caliper Replacement (1500 Series)  or Rear Brake Caliper Replacement (2500/3500 Series) 
    CAUTION: Do not place your fingers in front of the piston in order to catch or protect the piston while applying compressed air. This could result in serious injury.
  2. Place a thin piece wood in front of the pistons in order to prevent damage. Remove the pistons by directing compressed air into the brake hose inlet fitting port of the brake caliper housing
  3. Remove the 2 pistons
    4. Fig 2: View Of Brake Caliper Pistons, Boots & Seals
    GM369669
  4. Remove the 2 piston boots
  5. Remove the 2 piston seals
  6. Remove the brake caliper bleed screw cap
  7. Remove the brake caliper bleed screw
  8. Inspect the brake caliper bores and the piston seal grooves for scoring and corrosion. If you find excessive scoring or corrosion around the 2 piston seal areas replace the brake caliper housing
    9. Fig 3: View Of Brake Caliper Mounting Bracket
    GM369671
  9. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed
  10. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket
  11. Clean all the parts not included in the repair kit with denatured alcohol
  12. Dry all the parts with non lubricated filtered compressed air.
  13. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve
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