Disassembly (2500 & 3500 Series)
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Remove the brake caliper from the vehicle. See BRAKE CALIPERS under REMOVAL & INSTALLATION.
- 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. Remove the 2 pistons. See Fig 1 .
- Remove the 2 piston boots. Remove the 2 piston seals. See Fig 1 . Remove the brake caliper bleed screw cap. Remove the brake caliper bleed screw.
- 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.
- Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed. Clean all the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket.
- Clean all the parts not included in the repair kit with denatured alcohol. Dry all the parts with non lubricated filtered compressed air. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve.