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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) >> Disassembly Procedure

Disassembly Procedure

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  1. Remove the brake caliper. Refer to Front Brake Caliper Replacement (1500 Series)  or Front Brake Caliper Replacement (2500 Series) .
  2. Drain all the brake fluid from the caliper.
    3. 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.
    IMPORTANT: The brake calipers use phenolic pistons that have stainless steel caps which contact the brake pads. Use compressed air to remove the piston from the brake caliper.
  3. Secure the brake caliper in a suitable holding device.
  4. Insert a piece of wood in the brake caliper between the pistons and the outer bridge.
    5. Fig 1: Applying Air To Brake Caliper
    GM1363959Courtesy of GENERAL MOTORS CORP.
  5. Cover the brake caliper with a shop towel.
  6. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper.
    7. Fig 2: Clamping Brake Caliper
    GM800797Courtesy of GENERAL MOTORS CORP.
  7. If one of the pistons fails to be removed from the brake caliper, perform the following steps.
    1. Reposition the piston that has been removed back into the brake caliper.
    2. Using a small block of wood and a C-clamp, slowly tighten the C-clamp until the piston is half way into the brake caliper. It does not have to be fully seated.
    3. Position a second block of wood in front of the piston that remains in the brake caliper.
    4. Cover the brake caliper with a shop towel.
    5. Apply filtered, non-lubricated compressed air into the brake hose inlet fitting port of the brake caliper.
    8. Fig 3: Exploded View Of Brake Caliper
    GM1339829Courtesy of GENERAL MOTORS CORP.
  8. Remove the pistons (3) from the caliper bores.
  9. Remove the boots (4) from the caliper bores. Do not scratch the caliper bores.
  10. Remove the piston seals (2) from the caliper bores. Do not use a metal tool.
  11. Remove the bleeder valve cap (5).
  12. Remove the bleeder valve (6) from the caliper housing (1).
  13. Clean the bleeder valve, the caliper bores, the caliper passages and the pistons with denatured alcohol. Dry the parts and blow out the brake fluid passages using filtered, non-lubricated compressed air.
  14. Replace the pistons or the caliper if any of the following conditions exist:
    • Scoring in the caliper bores
    • Corrosion in the caliper bores
    • Pitting in the caliper bores
    • Damage to the pistons (phenolic)
  15. Clean the brake caliper assembly with denatured alcohol.
  16. Dry with filtered, non-lubricated compressed air.
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