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Home >> Hummer >> 2008 >> H2 4D Utility Wagon >> Repair and Diagnosis >> External Pages >> Different car >> Section 213 (Disc Brake System) >> Repair Instructions >> Front Brake Caliper Overhaul (2500 Series) >> Assembly Procedure

Assembly Procedure

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    IMPORTANT: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material.
  1. Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore.
    2. Fig 1: View Of Brake Caliper Piston Seal
    GM1339828Courtesy of GENERAL MOTORS CORP.
  2. Install the square-cut piston seal in the brake caliper bore groove.
  3. Ensure that the square-cut piston seal is not twisted.
    4. Fig 2: View Of Piston Dust Seal
    GM1339826Courtesy of GENERAL MOTORS CORP.
  4. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening.
    5. Fig 3: Installing Piston To Brake Caliper
    GM1339824Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Position the piston in the bore so that it is straight and level.
  5. Position the piston to the brake caliper bore and seat the boot into the brake caliper bore groove.
    6. Fig 4: Installing Piston Into Bore
    GM1364318Courtesy of GENERAL MOTORS CORP.
  6. Position a piece of wood across the piston to be installed.
  7. Applying equal pressure by hand while pushing down, install the piston in the bore.
  8. Remove the piece of wood.
    9. Fig 5: View Of Bleeder Valve Cap
    GM800798Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  9. Install the bleeder valve in the brake caliper housing.

    Tighten:  Tighten the bleeder valve to 12 N.m (106 lb in).

  10. Install the bleeder valve cap.
  11. Install the brake caliper. Refer to Front Brake Caliper Replacement (1500 Series)  or Front Brake Caliper Replacement (2500 Series) .
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