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Home >> GMC >> 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 (2500/3500 Series) >> Removal Procedure

Removal 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: Installing C-Clamp Over Brake Caliper - Rear
    GM687185
  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
  5. Remove the tire and wheel assembly
  6. Inspect the caliper operation. Refer to Brake Caliper Inspection  
  7. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad
  8. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads
  9. Remove the C-clamp from the caliper
    10. Fig 2: View Of Brake Hose To Caliper - Rear
    GM363420
  10. 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
  11. Remove the brake hose to caliper bolt from the brake caliper
  12. Remove the brake hose from the caliper
  13. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end
  14. Loosen the brake caliper mounting bolts. Do not remove
    15. Fig 3: View Of Rear Caliper Mounting Bolts
    GM913587
  15. CAUTION: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result
  16. Remove the brake caliper and the brake caliper mounting bracket as an assembly
  17. Remove the brake caliper mounting bolts
  18. Remove the brake caliper from the brake caliper mounting bracket
  19. Inspect the caliper assembly. Refer to Brake Caliper Inspection  
    20. Fig 4: View Of Disc Brake Pads & Brake Caliper Mounting Bracket
    GM369668
  20. Remove the brake pads from the brake caliper mounting bracket
  21. Remove the anti-rattle clips from the brake caliper mounting bracket
  22. Inspect the brake caliper mounting bracket for cracks and/or damage. Replace if necessary
  23. Inspect the brake caliper mounting bracket bushings for damage and/or wear. Replace the bushings if necessary.
  24. Perform the following procedure to replace the brake caliper mounting bracket bushings.
    • Insert a flat bladed tool between the bushing flange and the mounting bracket
    • Work the tool around the bushing flange and remove the bushing from the mounting bracket
    • Place a socket over the boot onto the bushing flange and install the bushing to the mounting bracket
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