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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 Replacement (1500 Series) >> Installation Procedure

Installation 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.
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
    Fig 1: Lifting Inner Edge Of Caliper Boot - Rear
    GM177028
    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).
    1. 4.1. Remove all traces of the original adhesive patch.
    2. 4.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
    3. 4.3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt
    5. Fig 2: Locating Caliper Guide Pin Bolts
    GM913489
  5. Install the caliper guide pin bolts
  6. Tighten the caliper guide pin bolts. Tighten the caliper guide pin 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. Fig 3: View Of Brake Hose To Caliper - Rear
    GM363420
  9. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. Tighten the bolt to 40 N.m (30 lb ft).
  10. Bleed the hydraulic brake system. Refer to HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL) in Hydraulic Brakes.
  11. Install the tire and wheel assembly
  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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