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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 Replacement - Rear (1500 Series) >> Installation Procedure

Installation 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: 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.
    2. 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. Fig 1: Lifting Inner Edge Caliper Boot - Rear (1500 Series)
    GM177028Courtesy of GENERAL MOTORS CORP.
  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. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
    3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
  5. Install the caliper guide pin bolts.
    6. Fig 2: Installing Caliper Guide Pin Bolts - Rear (1500 Series)
    GM913489Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Tighten the caliper guide pin bolts.

    Tighten:  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.
    8. 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. Connect the brake hose at the caliper by installing the brake hose to caliper bolt.

    Tighten:  Tighten the bolt to 40 N.m (30 lb ft).

    10. Fig 3: View Of Brake Hose To Caliper - Rear
    GM363420Courtesy of GENERAL MOTORS CORP.
  10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  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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