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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1011 (Disc Brake System) >> Repair Instructions >> Brake Caliper Overhaul - Rear (25/35 Series) >> Disassembly Procedure

Disassembly Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
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 Brake Caliper Replacement - Rear (1500 Series)  or Brake Caliper Replacement - Rear (2500/3500 Series) .
    2. 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 1: Exploded View Of Rear Brake Caliper (25/35 Series)
    GM369865Courtesy of GENERAL MOTORS CORP.
  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. Fig 2: View Of Brake Caliper Pistons, Boots & Seals
    GM369669Courtesy of GENERAL MOTORS CORP.
  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. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed.
    10. Fig 3: View Of Brake Caliper Mounting Bracket
    GM369671Courtesy of GENERAL MOTORS CORP.
  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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