Disc Brake System Chevrolet Express G2500

Fastener Tightening Specifications

Fastener Tightening Specifications

Disc Brake Component Specifications

Disc Brake Component Specifications

Brake Rotor Thickness Measurement

1. Clean the brake pad lining contact surface of the brake rotor with denatured alcohol or an equivalent brake cleaner.
2. Using a calibrated micrometer measure and record the lowest thickness of the brake rotor at 4 or more points equally spaced around the rotor. Ensure that the measurements are only taken within the brake pad lining contact area and that the micrometer is positioned the same distance from the outside edge of the rotor for each measurement.
3. Compare the lowest thickness measurement recorded to the following specifications: Specification - Front Brake JH5 Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) Brake rotor discard thickness 27.50 mm (1.083 in) Specification - Front Brake JH6/JH7 Brake rotor minimum allowable thickness after refinishing 37.0 mm (1.457 in) Brake rotor discard thickness 36.50 mm (1.437 in) Specification - Rear Brake JH5 Brake rotor minimum allowable thickness after refinishing 29.0 mm (1.142 in) Brake rotor discard thickness 28.50 mm (1.122 in) Specification - Rear Brake JH6/JH7 Brake rotor minimum allowable thickness after refinishing 28.0 mm (1.102 in) Brake rotor discard thickness 27.50 mm (1.083 in)
4. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification then the rotor may be refinished, depending upon surface and wear conditions which may be present.
5. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification then the rotor may not be refinished.
6. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification then the rotor requires replacement.

Brake Rotor Thickness Variation Measurement

Note. Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation.

1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to «Front Disc Brake Pads Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Disc Brake Pads Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-disc-brake-pads-replacement-jh5) , and/or «Rear Disc Brake Pads Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Disc Brake Pads Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Using a micrometer (1) calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at 4 or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the amount of thickness variation.
5. Compare the thickness variation measurement to the following specification: Specification Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in)
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement.

Brake Rotor Surface and Wear Inspection

Special Tools

J 8001 Dial Indicator set, or Equivalent

1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, clean the braking/friction surfaces of the brake rotor with denatured alcohol or an equivalent approved brake cleaner.
2. Inspect the braking surfaces of the brake rotor for the following braking surface conditions: Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc; heavy surface rust and/or pitting must be removed by refinishing the rotor. Cracks and/or heat spots Excessive blueing discoloration
3. If the braking surfaces of the brake rotor exhibits one or more of the braking surface conditions, the rotor requires refinishing or replacement.
4. Using a calibrated micrometer measure and record the thickness variation of the brake rotor at 4 or more points around the brake rotor. Ensure that the measurements are only taken within the brake pad lining contact area and that the micrometer is positioned the same distance from the outside edge of the rotor for each measurement.
5. Compare the thickness variation recorded to the following specification: Specification Brake rotor maximum allowable thickness variation 0.025 mm (0.001 in).
6. If the brake rotor thickness variation exceeds the specification, the rotor requires refinishing or replacement.
7. Using the micrometer measure and record any grooves present on the rotor braking surface.
8. Compare the groove/scoring depth recorded to the following specification: Specification Brake rotor maximum allowable scoring 1.50 mm (0.059 in).
9. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement.
10. Mount a dial indicator J 8001 Dial Indicator set, or Equivalent and position the indicator button so it contacts the brake rotor at a 90 degree angle, approximately 13 mm (0.5 in) from the rotor's outer edge.
11. Measure and record the lateral runout of the brake rotor. Rotate the rotor until the lowest reading is displayed on the indicator dial and zero the dial. Rotate the rotor until the highest reading is displayed on the dial. Measure and record the amount of lateral runout.
12. Compare the lateral runout of the brake rotor to the following specification: Specification Brake rotor maximum allowable lateral runout 0.05 mm (0.002 in).
13. If the brake rotor lateral runout exceeds the specification the rotor requires refinishing or replacement.

Brake Rotor Assembled Lateral Runout Measurement

Special Tools

1. J-39544-KIT Torque-Limiting Socket Set, or equivalent
2. J-41013 Rotor Resurfacing Kit
3. J-42450-A Wheel Hub Resurfacing Kit
4. J-45101 Hub and Wheel Runout Gauge
5. J-45101-100 Conical Brake Rotor Washers

Note. Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4, 800-11, 300 km (3, 000-7, 000 mi). Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement .

1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: Remove the brake rotor from the vehicle. Refer to «Front Brake Rotor Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Rotor Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , and/or «Rear Brake Rotor Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Rotor Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) . Using the J-42450-A Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. Using the J-41013 Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the brake rotor. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the J-45101-100 Conical Brake Rotor Washers (1), and one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining J-45101-100 Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern.
7. Using the J-39544-KIT Torque-Limiting Socket Set, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14.
9. If the brake rotor meets the following criteria, proceed to step 10. The rotor is within specifications and is being REUSED The rotor has NOT been refinished The rotor does NOT exhibit thickness variation exceeding the maximum allowable level
10. Mount a dial indicator, J-45101 Hub and Wheel Runout Gauge, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
11. Measure and record the assembled LRO of the brake rotor. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. Rotate the rotor until the highest reading is displayed on the dial. Mark the location of the high spot relative to the nearest wheel stud, or studs. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specifications: Specification Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in)
13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism, refer to «Brake Rotor Refinishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-refinishing) . After refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, J-45101 Hub and Wheel Runout Gauge, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor.
15. Measure and record the assembled LRO of the brake rotor. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. Rotate the rotor until the highest reading is displayed on the dial. Mark the location of the high spot relative to the nearest wheel stud, or studs. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specifications: Specification Brake rotor maximum allowable assembled lateral runout: 0.13 mm (0.005 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J-45101-100 Conical Brake Rotor Washers and the lug nuts.

Brake Pad Inspection

1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle.
2. If replacement is necessary, always replace disc brake pads in axle sets.
3. Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads.
4. Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set.
5. Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation.
6. Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates.
7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads.
8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance.
9. Replace the disc brake pads if any have separated from the mounting plates.
10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance.

Brake Caliper Inspection

1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores.

Front Disc Brake Mounting and Hardware Inspection

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Grasp the brake caliper housing and try to move the brake caliper housing up/down and forward/reverse in relation to the brake caliper mounting bracket. If excessive looseness is observed the brake caliper bracket bushings and/or the brake caliper mounting bolts may need to be replaced.
7. Compress the front caliper pistons. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. Remove the C-clamp from the caliper.
8. With the pistons compressed into the caliper bores, grasp the brake caliper housing and slide it back and forth on the brake caliper mounting bolts. Check for smooth operation. If the brake caliper housing slide force is high or the brake caliper housing does not slide smoothly, inspect the brake caliper mounting bolts and/or the brake caliper mounting bracket bushings for wear or damage. If wear or damage conditions are found, replacement of the brake caliper mounting bolts and/or the brake caliper mounting bracket bushings is necessary.
9. Remove the brake caliper mounting bolts from the brake caliper mounting bracket and support the brake caliper using heavy mechanics wire. Do Not remove the hydraulic brake hose from the caliper. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
10. Remove the disc brake pads from the brake caliper mounting bracket.
11. Inspect the disc brake pad mounting hardware for the following: Missing mounting hardware Excessive corrosion Bent mounting tabs Looseness at the brake caliper mounting bracket Looseness at the disc brake pads Excessive contaminants in the brake caliper mounting bracket surface and threads.
12. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
13. Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket, yet slide easily on the mounting hardware without binding.
14. Inspect the caliper bolts (1) for the following: Binding Seizing Looseness in the brake caliper mounting bracket (3) Bent or damaged brake caliper mounting bolts Cracked or torn boots (4) Missing boots Bent or damaged brake caliper mounting bracket (3)
15. If any of the conditions listed are found then the brake caliper mounting hardware requires replacement.
16. Install the disc brake pads to the brake caliper mounting bracket.
17. Install the disc brake caliper to the brake caliper mounting bracket. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .

Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Grasp the brake caliper housing and try to move the brake caliper housing up/down and forward/reverse in relation to the brake caliper mounting bracket. If excessive looseness is observed the brake caliper bracket bushings and/or the brake caliper mounting bolts may need to be replaced.
7. Compress the rear brake caliper pistons. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. Remove the C-clamp from the caliper.
8. With the pistons compressed into the caliper bores, grasp the brake caliper housing and slide it back and forth on the brake caliper mounting bolts. Check for smooth operation. If the brake caliper housing slide force is high or the brake caliper housing does not slide smoothly, inspect the brake caliper mounting bolts and/or the brake caliper mounting bracket bushings for wear or damage. If wear or damage conditions are found, replacement of the brake caliper mounting bolts and/or the brake caliper mounting bracket bushings is necessary.
9. Remove the brake caliper mounting bolts from the brake caliper mounting bracket and support the brake caliper using heavy mechanics wire. Do Not remove the hydraulic brake hose from the caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
10. Remove the disc brake pads from the brake caliper mounting bracket.
11. Inspect the disc brake pad mounting hardware for the following: Missing mounting hardware Excessive corrosion Bent mounting tabs Looseness at the brake caliper mounting bracket Looseness at the disc brake pads Excessive contaminants in the brake caliper mounting bracket surface and threads.
12. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
13. Ensure the disc brake pads are held firmly in place on the brake caliper mounting bracket, yet slide easily on the mounting hardware without binding.
14. Inspect the caliper bolts (1) for the following: Binding Seizing Looseness in the brake caliper mounting bracket (3) Bent or damaged brake caliper mounting bolts Cracked or torn boots (4) Missing boots Bent or damaged brake caliper mounting bracket (3)
15. If any of the conditions listed are found then the brake caliper mounting hardware requires replacement.
16. Install the disc brake pads to the brake caliper mounting bracket.
17. Install the disc brake caliper to the brake caliper mounting bracket. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .

Rear Disc Brake Mounting and Hardware Inspection (With Dual Rear Wheel)

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Install a large C-clamp, over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
5. Tighten the C-clamp until the caliper piston is compressed into the caliper bore leaving a gap of approximately 10 mm (0.38 in) between the disc brake pads and the brake rotor.
6. Remove the C-clamp from the caliper.
7. Grasp the brake caliper and attempt to move the brake caliper vertically. The brake caliper should not exhibit excessive looseness.
8. Grasp the brake caliper and move the brake caliper inboard and outboard. The brake caliper should slide smoothly with minimal force.
9. Inspect the disc brake pad retainers and the disc brake pads for the following: Bent mounting tabs Excessive corrosion Looseness at the caliper bracket Looseness at the disc brake pads Missing mounting hardware
10. If any of the conditions listed are found, the disc brake pads and/or mounting hardware require replacement.
11. Ensure the disc brake pads are held firmly in place on the caliper bracket, yet slide easily on the bracket without binding.
12. Inspect the brake caliper guide pin seals (1) and the brake caliper guide pin caps (2) for the following: Split or torn seals Split or torn caps Missing seals Missing caps
13. Inspect the brake caliper mounting hardware for the following: Dislodged and distorted seals (1) at the brake caliper Dislodged and distorted seals at the brake caliper bracket Hardened brake caliper guide pin seals Seized brake caliper guide pins (2) Bent or damaged brake caliper guide pins Restricted brake caliper sliding movement Dislodged and distorted brake caliper guide pin caps (3) Hardened brake caliper guide pin caps
14. If any of the conditions listed are found, the brake caliper mounting hardware requires replacement.

Removal Procedure

Note. Always replace disc brake pads in axle sets.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Inspect the caliper operation. Refer to «Brake Caliper Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-inspection) .
7. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
8. Remove the brake pads from the caliper mounting bracket.
9. Remove and discard the anti-rattle clips from the brake caliper mounting bracket.
10. Inspect the caliper and mounting bracket. Refer to «Brake Caliper Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-inspection) .

Installation Procedure

1. Install new anti-rattle clips to the inside ends of the caliper mounting bracket.
2. Install the brake pads to the caliper mounting bracket.
3. Place the new pads in the same orientation as noted during removal.
4. Install the brake caliper. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
5. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Remove the safety stands.
7. Lower the vehicle.
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-9 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
11. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
12. Burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

Front Disc Brake Pads Replacement (JH5)

Note. Always replace disc brake pads in axle sets.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum-full point and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Compress the brake caliper pistons. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. Remove the C-clamps from the caliper.
7. Using an open end wrench to hold the guide pin, loosen the brake caliper guide pin bolt.
8. Remove the lower brake caliper guide pin bolt (1).
9. Rotate the brake caliper (2) upward until it rests on the brake caliper mounting bracket and support with heavy mechanics wire or equivalent.
10. Remove the brake pads (3).
11. Remove the brake pad spring clips (4) from the mounting bracket (5).
12. Thoroughly clean the pad hardware mating surfaces of the caliper bracket of any corrosion or debris with denatured alcohol and allow to dry.
13. If installing new brake pads, thoroughly clean the brake caliper piston faces and caliper housing to brake pad contact surfaces of all disc brake pad insulator adhesive residue with denatured alcohol and allow to dry.

1. Apply a very thin coating of high temperature silicone brake lubricant to the pad mating surfaces of the caliper bracket only.
2. Install the spring clips (4) to the mounting bracket. Install the NEW spring clips if replacing the brake pads. Install the original spring clips in their original position if installing the original brake pads.
3. If installing new brake pads, remove the adhesive backing paper from the brake pad insulators.
4. Install the brake pads (3).
5. Rotate the brake caliper (2) into the proper position on the mounting bracket (5).
6. Use an open end wrench to hold the caliper guide pin while tightening the brake caliper guide pin bolt to 100 N.m (74 lb ft).
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. Lower the vehicle.
9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
10. Slowly release the brake pedal.
11. Wait 15 seconds, then repeat steps 9-10 until a firm pedal is obtained to properly seat the brake caliper pistons and pads.
12. Fill the brake master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
13. Firmly apply and maintain pressure on the brake pedal for 30 seconds to seat the brake pad insulators to the brake caliper pistons and caliper housing. Repeat this step 1 additional time.
14. Burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

Note. Always replace disc brake pads in axle sets.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Inspect the caliper operation. Refer to «Brake Caliper Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-inspection) .
7. Place a C-clamp as shown. Slowly bottom the pistons of the caliper. It may be necessary to reposition the C-clamp to allow both of the pistons to bottom into the caliper bores.
8. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
9. Inspect the caliper assembly. Refer to «Brake Caliper Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-inspection) .
10. Remove the brake pads from the brake caliper bracket. Note the orientation.
11. Remove and discard the anti-rattle clips from the brake caliper mounting bracket.

1. Install the anti-rattle clips to the brake caliper bracket.
2. Install the brake caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
3. Install the brake pads to the brake caliper bracket. Place the new pads in the same orientation as noted during removal.
4. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
5. Lower the vehicle.
6. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
7. Slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
9. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
10. Burnish the brakes pads and rotors as necessary. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

Note. Always replace disc brake pads in axle sets.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Position a large C-clamp against the outboard disc brake pad backing plate and over the rear of the brake caliper body.
7. Using the C-clamp, slowly and evenly bottom the brake caliper pistons into the brake caliper bores.
8. Remove the brake caliper bracket bolts (1).
9. Remove the brake caliper and bracket assembly (1) and support with heavy mechanics wire or equivalent.
10. Remove the outer brake pad (1).
11. Remove the inner brake pad (2).
12. Remove the brake pad springs (1).
13. Clean the brake pad springs contact areas of the brake caliper bracket of any accumulated corrosion and debris.

1. Ensure the brake caliper guide pin caps (1) are in good condition and firmly seated on the brake caliper body. Replace any missing or damaged brake caliper guide pin caps.
2. Without disengaging the brake caliper from the brake caliper guide pins, inspect the brake caliper hardware. Refer to «Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) , «Rear Disc Brake Mounting and Hardware Inspection (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) .
3. Install the brake pad springs (1).
4. Install the outer brake pad (1).
5. Install the inner brake pad (2).
6. Prepare the brake caliper bracket bolts and the rear axle threaded holes for assembly. Clean the brake caliper bracket bolts of any threadlocking residue Clean the rear axle threaded holes of any threadlocking residue with denatured alcohol and allow to dry
7. Apply threadlocker GM P/N 89021297 (Canadian P/N 10953488) to 2/3 of the threaded length of the brake caliper bracket bolt.
8. Allow the threadlocker to cure approximately 10 minutes before assembly.
9. Position the brake caliper and bracket assembly (1) to the rear axle.
10. Install the brake caliper bracket bolts (1) and tighten to 300 Y (221 lb ft).
11. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
13. Slowly release the brake pedal.
14. Wait 15 seconds, then repeat steps 14-15 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
15. Fill the brake master cylinder. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
16. Burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

Brake Pad and Rotor Burnishing

Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system.

This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced.

1. Select a smooth road with little or no traffic.
2. Accelerate the vehicle to 48 km/h (30 mph). NOTE: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Compress the brake caliper pistons. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. Remove the C-clamp from the caliper.
7. Clean all dirt and foreign material from the brake hose end.
8. Remove the brake hose to caliper bolt from the brake caliper.
9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
10. Remove the brake hose from the caliper.
11. Remove the 2 brake caliper mounting bolts.
12. Remove the brake caliper from the brake caliper mounting bracket.

1. Install the brake caliper to the brake caliper mounting bracket.
2. Perform the following procedure before installing the caliper mounting bolts. Remove all traces of the original adhesive patch. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
3. Install the 2 brake caliper mounting bolts and tighten to 108 N.m (80 lb ft).
4. Remove the rubber cap or plug from the exposed brake hose fitting end.
5. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.
6. Install the brake hose to caliper bolt to the brake caliper and tighten to 44 N.m (32 lb ft).
7. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Pressure)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) , «Hydraulic Brake System Bleeding (Manual)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
9. Lower the vehicle.
10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .

Front Brake Caliper Replacement (JH5)

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Compress the brake caliper pistons. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamps until the pistons are pushed completely into the caliper bores. Remove the C-clamps from the caliper.
7. Clean all dirt and foreign material from the brake caliper.
8. Remove the brake hose to caliper bolt.
9. Remove and discard the 2 copper brake hose gaskets.
10. Remove the brake hose from the brake caliper.
11. Using an open end wrench to hold the guide pin, loosen the brake caliper bolts.
12. Remove the brake caliper bolts.
13. Remove the brake caliper from the mounting bracket.

1. Install the caliper to the caliper bracket.
2. Install the brake caliper bolts.
3. Using an open end wrench to hold the guide pins while tightening the brake caliper bolts to 100 N.m (74 lb ft).
4. Remove the cap or plug from the brake hose fitting end.
5. Install the brake hose to caliper bolt and tighten to 44 N.m (32 lb ft).
6. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Pressure)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) , «Hydraulic Brake System Bleeding (Manual)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Compress the brake caliper pistons. Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad. Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores. Remove the C-clamp from the caliper.
7. Clean all dirt and foreign material from the brake hose end.
8. Remove the brake hose fitting bolt from the brake caliper.
9. Cap the brake hose fitting to prevent brake fluid loss and contamination.
10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
11. Remove the caliper guide pin bolts.
12. Remove the brake caliper from the vehicle.
13. Inspect the caliper assembly. Refer to «Brake Caliper Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-caliper-inspection) .

1. If you are installing new brake pads use a C-clamp in order to compress the pistons to the bottom of the caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in order to protect the pistons and the caliper boots.
2. Ensure that the caliper boots are below the level of the face of both pistons.
3. Install the brake caliper to the brake caliper mounting bracket.
4. Perform the following procedure before installing the caliper guide pin bolts. Remove all traces of the original adhesive patch. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
5. Install the rear brake caliper guide pin bolts.
6. Tighten the rear brake caliper guide pin bolts. Tighten the bolts to 34 N.m (25 lb ft) (JH5). Tighten the bolts to 72 N.m (53 lb ft) (JH6).
7. Remove the cap from the brake hose fitting end.
8. Assemble 2 NEW copper brake hose gaskets and the brake hose fitting bolt to the brake hose.
9. Install the brake hose assembly to the brake caliper and tighten the brake hose fitting bolt to 44 N.m (32 lb ft).
10. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Pressure)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) , «Hydraulic Brake System Bleeding (Manual)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
11. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
12. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level then no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level then remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. Position a large C-clamp against the outboard disc brake pad backing plate and over the rear of the brake caliper body.
7. Using the C-clamp, slowly and evenly bottom the brake caliper pistons into the brake caliper bores.
8. Remove the brake hose fitting bolt (1).
9. Remove and discard the brake hose fitting gaskets (2) from the brake hose (3). Cap the brake hose fitting to prevent brake fluid loss and contamination.
10. Remove the brake caliper bracket bolts (1).
11. Remove the brake caliper and bracket assembly.
12. Remove the outer brake pad (1).
13. Remove the inner brake pad (2).
14. Remove the brake pad springs (1).
15. Slide the brake caliper (1) off of the brake caliper guide pins and the caliper bracket.
16. Inspect the brake caliper mounting and hardware for damage and wear. Refer to «Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) , «Rear Disc Brake Mounting and Hardware Inspection (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) .
17. Remove the brake caliper guide pin seals (1) and the brake caliper guide pin caps (2).

1. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide pin bores.
2. Install the brake caliper guide pin seals (1) Ensure the brake caliper guide pin seals are fully seated in the groove of the brake caliper housing.
3. Install the brake caliper guide pin caps (2). Ensure the brake caliper guide pin caps are fully seated in the groove of the brake caliper housing.
4. Slide the brake caliper (1) on to the brake caliper guide pins and the caliper bracket. Ensure the brake caliper guide pin seals are fully seated in the groove of the brake caliper bracket.
5. Install the brake pad springs (1).
6. Prepare the brake caliper bracket bolts and the rear axle threaded holes for assembly. Clean the brake caliper bracket bolts of any threadlocking residue Clean the rear axle threaded holes of any threadlocking residue with denatured alcohol and allow to dry
7. Apply threadlocker GM P/N 89021297 (Canadian P/N 10953488) to 2/3 of the threaded length of the brake caliper bracket bolt.
8. Allow the threadlocker to cure approximately 10 minutes before assembly.
9. Position the brake caliper and bracket assembly (1) to the rear axle.
10. Install the brake caliper bracket bolts (1) and tighten to 300 Y (221 lb ft).
11. Assemble the brake hose fitting bolt (1) and 2 new brake hose fitting gaskets (2) to the brake hose (3).
12. Tighten the brake hose fitting bolt to 40 N.m (30 lb ft).
13. Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Pressure)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) , «Hydraulic Brake System Bleeding (Manual)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system) .
14. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .

Front Brake Caliper Overhaul (JH6, JH9)

Disassembly Procedure

1. Remove the brake caliper from the vehicle. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
2. Place a thin piece of wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing.
3. Remove the piston boot.
4. Remove the piston seal.
5. Remove the brake caliper bleed screw cap.
6. Remove the brake caliper bleed screw.
7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing.
8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if necessary.
9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket.
10. Clean all of the parts not included in the repair kit with denatured alcohol.
11. Dry all of the parts with filtered unlubricated compressed air.
12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve.

Assembly Procedure

1. Install the brake caliper bleed screw and tighten to 12 N.m (106 lb in).
2. Install the brake caliper bleed screw cap.
3. Lubricate the new piston seals and the brake caliper bore seal grooves with brake fluid, GM P/N 12388967 (Canadian P/N 992667).
4. Install new seals into the brake caliper bore seal grooves.
5. Ensure that the seals are not twisted.
6. Lubricate the brake caliper bores and the pistons with brake fluid, GM P/N 12388967 (Canadian P/N 992667).
7. Install the boot and piston. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. Push down the piston to the bottom of the brake caliper bore. Ensure the boot seats properly into the piston groove and into the groove in the brake caliper bore. Repeat step 7 for the remaining piston.
8. Install the brake caliper to the vehicle. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .

Rear Brake Caliper Overhaul (JH5)

Note. 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 «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
2. Place a thin piece wood in front of the piston in order to prevent damage. Remove the piston by directing compressed air into the brake hose inlet fitting port of the brake caliper housing.
3. Remove the piston boot.
4. Remove the piston seal.
5. Remove the brake caliper bleed screw cap.
6. Remove the brake caliper bleed screw.
7. Inspect the brake caliper bore and the piston seal groove for scoring and corrosion. If you find excessive scoring or corrosion around the piston seal area, replace the brake caliper housing.
8. Inspect the brake caliper mounting bracket guide surfaces for corrosion and wear. Remove and replace the brake caliper mounting bracket if needed.
9. Clean all of the residue from the brake pad guiding surfaces on the brake caliper housing and the brake caliper mounting bracket.
10. Clean all of the parts not included in the repair kit with denatured alcohol.
11. Dry all the parts with non lubricated filtered compressed air.
12. Blow out all passages in the brake caliper housing and the brake caliper bleeder valve.

1. Install the brake caliper bleed screw and tighten to 12 N.m (106 lb in).
2. Install the brake caliper bleed screw cap.
3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid.
4. Install the new seal into the brake caliper bore seal groove.
5. Ensure that the seal is not twisted.
6. Lubricate the brake caliper bore and the piston with brake fluid.
7. Install the boot and piston. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. Push down the piston to the bottom of the brake caliper bore. Ensure that the boot is properly seats into the piston groove and into the groove in the brake caliper bore.
8. Install the brake caliper to the vehicle. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .

Rear Brake Caliper Overhaul (JH6)

Scheme 9

Note. 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 «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
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. 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. 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. 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.

1. Install the brake caliper bleed screw and tighten to 12 N.m (106 lb in).
2. Install the brake caliper bleed screw cap.
3. Lubricate the new piston seal and the brake caliper bore seal groove with brake fluid.
4. Install new the seal into the brake caliper bore seal groove.
5. Ensure that the seal is not twisted.
6. Lubricate the brake caliper bore and the piston with brake fluid.
7. Install the boot and the piston. Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening. Seat the boot into the brake caliper bore groove. Slide the piston into the brake caliper bore. Push down the piston to the bottom of the brake caliper bore. Ensure that the boot properly seats into the piston groove and into the groove in the brake caliper bore. Repeat steps 5 and 6 for the remaining piston.
8. Install the brake caliper to the vehicle. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .

Special Tools

1. J-8092 Driver Handle
2. J-45515 Piston Seal Installer

1. Remove the brake caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
2. Place a wood block between the brake caliper pistons and the brake caliper housing bridge.
3. Place a clean shop towel between the brake caliper pistons and the block of wood.
4. Apply compressed air through the brake hose fitting inlet port and remove the brake caliper pistons (1).
5. Remove the brake caliper bleeder screw.
6. Using a blunt wooden or plastic tool, remove the brake caliper piston dust seals (1).
7. Using a blunt wooden or plastic tool, remove the brake caliper piston seals (1).
8. Inspect the brake caliper bores for corrosion, grooves, and scoring. Inspect the caliper piston bores Inspect the caliper piston seal grooves If excessive corrosion, grooving, or scoring is found, replace the brake caliper.
9. Clean the brake caliper housing and any parts to be reused with denatured alcohol.
10. Dry all components with dry, filtered, non-lubricated compressed air.

1. Apply a light coating of GM approved brake fluid from a clean, sealed brake fluid container to the brake caliper components: Brake caliper piston bores Brake caliper pistons Brake caliper piston seals
2. Install the brake caliper piston seals (1) to the brake caliper piston bores. Ensure the brake caliper piston seals are fully seated in the groove of the caliper piston bores and are not distorted.
3. Using the J-45515 Piston Seal Installer with the J-8092 Driver Handle, install the brake caliper piston dust seals (1).
4. Install the brake caliper pistons (1) into the brake caliper housing. Use firm, downward hand pressure to press the brake caliper pistons squarely into the caliper bores.
5. Seat the edge of the brake caliper dust seals in the groove in the brake caliper piston.
6. If necessary, carefully lift the edge of the brake caliper dust seals at the brake caliper piston to release any trapped air.
7. Install the brake caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .

Front Brake Caliper Hardware Replacement (JH6, JH9)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
4. Remove the disc brake pads from the disc brake caliper mounting bracket.
5. Remove the disc brake pad retainers from the disc brake caliper mounting bracket.
6. Inspect the disc brake hardware. Refer to «Front Disc Brake Mounting and Hardware Inspection»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-disc-brake-mounting-and-hardware) .
7. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket (3).

1. Lubricate the front brake caliper bushings, bolts and seals with high temperature silicone brake lubricant.
2. Install the caliper pin boots (4) to the disc brake caliper mounting bracket (3).
3. Install the disc brake pad retainers to the disc brake caliper mounting bracket.
4. Install the disc brake pads to the disc brake caliper mounting bracket.
5. Install the disc brake caliper to the caliper mounting bracket. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
6. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
7. Slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.

Front Brake Caliper Hardware Replacement (JH5)

1. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
2. Remove the brake caliper from the caliper bracket. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
3. Remove the brake pads from the caliper bracket.
4. Remove the brake pad retainers.
5. Remove the caliper pins, seals, and bushings from the caliper bracket.

1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
2. Install the caliper pin bushings, seals and pins to the caliper bracket.
3. Install the brake pad retainers to the caliper bracket.
4. Install the brake pads.
5. Install the caliper to the caliper bracket. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
6. Slowly apply pressure to the brake pedal until a firm pedal is achieved.
7. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
8. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .

Rear Brake Caliper Hardware Replacement (JH5, JH6)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic wire or equivalent. DO NOT disconnect the hydraulic brake hose from the caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
4. Remove the disc brake pads from the brake caliper mounting bracket.
5. Remove the disc brake pad retainers from the brake caliper mounting bracket.
6. Remove the caliper slide pins (5) from the brake caliper mounting bracket (3).
7. Remove the caliper slide pin boots (4) from the brake caliper mounting bracket.
8. Inspect the disc brake hardware. Refer to «Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) , «Rear Disc Brake Mounting and Hardware Inspection (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) .

1. Lubricate the brake caliper mounting bracket bushings and the caliper slide pins with high temperature silicone brake lubricant.
2. Install the caliper slide pin boots (4) to the disc brake caliper mounting bracket.
3. Install the caliper slide pins (5) to the brake caliper mounting bracket (3).
4. Install the disc brake pad retainers to the brake caliper mounting bracket.
5. Install the disc brake pads to the brake caliper mounting bracket.
6. Install the disc brake caliper to the brake caliper mounting bracket. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
7. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
8. Slowly release the brake pedal.
9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
10. Lower the vehicle.

1. Remove the brake caliper bracket. Refer to «Rear Brake Caliper Bracket Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-jh5) , «Rear Brake Caliper Bracket Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
2. Remove the brake caliper guide pin seals (1).
3. Remove the brake caliper guide pin caps (2).
4. Remove the brake caliper upper guide pin (1).
5. Remove the lower brake caliper guide pin (2).
6. Inspect the rear disc brake hardware. Refer to «Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) , «Rear Disc Brake Mounting and Hardware Inspection (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) .

1. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide pin surfaces: Apply lubricant to the brake caliper guide pin shafts. Apply lubricant to the brake caliper guide pin seats. Apply lubricant to the brake caliper guide pin threads.
2. Install the upper brake caliper guide pin (1) and tighten to 61 N.m (45 lb ft).
3. Install the lower brake caliper guide pin (2) and tighten to 61 N.m (45 lb ft).
4. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide bores and seals.
5. Install the brake caliper guide pin seals (1) and caps (2), if removed. Ensure the brake caliper guide pin seals and caps are fully seated in the grooves of the brake caliper housing.
6. Install the rear disc brake caliper (1) to the brake caliper bracket. Ensure the brake caliper guide pin seals are fully seated in the grooves of the brake caliper bracket.
7. Install the brake caliper bracket. Refer to «Rear Brake Caliper Bracket Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-bracket-replacement-jh5) , «Rear Brake Caliper Bracket Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .

1. Without disconnecting the hydraulic brake hose, remove the brake caliper and support with heavy mechanics wire or equivalent. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
2. Remove the brake pads.
3. Remove the brake pad springs from the brake caliper bracket.
4. Remove the brake caliper bracket bolts (2).
5. Remove the brake caliper bracket (1).
6. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket.
7. Clean the mounting surface and threads of the brake caliper bracket.

1. Install the brake caliper bracket (1).
2. Prepare the brake caliper bracket bolts for installation: Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to 2/3 of the threaded portion of the brake caliper bracket bolt. Allow the threadlocker to cure approximately 10 minutes before installation.
3. Install the brake caliper bracket bolts (2) and tighten to 300 N.m (221 lb ft).
4. Install the brake pad springs to the brake caliper bracket.
5. Install the brake pads to the brake caliper bracket.
6. Install the brake caliper. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-9 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.

Front Brake Caliper Bracket Replacement (JH5)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Without disconnecting the brake hose from the caliper, remove the caliper and support with heavy mechanics wire or equivalent. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
4. Remove the brake pads and springs.
5. Remove the brake caliper bracket mounting bolts.
6. Remove the brake caliper bracket.

1. Install the brake caliper bracket.
2. Perform the following procedure before installing the brake caliper bracket bolts. Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
3. Install the brake caliper bracket mounting bolts and tighten to 175 N.m (129 lb ft).
4. Install the brake pad springs.
5. Install the brake pads.
6. Install the brake caliper to the bracket. Refer to «Front Brake Caliper Replacement (JH6, JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Front Brake Caliper Replacement (JH5)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-jh5) .
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .

Rear Brake Caliper Bracket Replacement (JH5, JH6)

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Without disconnecting the hydraulic brake hose, remove the brake caliper and support with heavy mechanics wire or equivalent. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
4. Remove the brake pads from the brake caliper mounting bracket.
5. Remove the brake pad springs from the brake caliper bracket.
6. Remove the brake caliper bracket bolts (2).
7. Remove the brake caliper bracket (1).
8. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket.
9. Clean the mounting surface and threads of the brake caliper bracket.

1. Install the brake caliper bracket (1).
2. Prepare the brake caiper bolts for installation: Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to 2/3 of the threaded portion of the brake caliper bracket bolts. Allow the threadlocker to cure approximately 10 minutes before installation.
3. Install the brake caliper bracket bolts (2) and tighten to 200 N.m (148 lb ft).
4. Install the brake pad springs to the brake caliper mounting bracket.
5. Install the brake pads to the brake caliper mounting bracket.
6. Install the brake caliper. Refer to «Rear Brake Caliper Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Caliper Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
7. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
9. Slowly release the brake pedal.
10. Wait 15 seconds, then repeat steps 8-9 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.

1. Remove the rear disc brake pads. Refer to «Rear Disc Brake Pads Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Disc Brake Pads Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
2. Remove the rear disc brake caliper (1) from the brake caliper bracket and support with heavy mechanics wire or equivalent.
3. If necessary, remove the upper brake caliper guide pin (1).
4. If necessary, remove the lower brake caliper guide pin (2).
5. Inspect the brake caliper guide pin seals (1) and caps (2) for damage and wear. Refer to «Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) , «Rear Disc Brake Mounting and Hardware Inspection (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__rear-disc-brake-mounting-and-hardware) .

1. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide pin surfaces: Apply lubricant to the brake caliper guide pin shafts. Apply lubricant to the brake caliper guide pin seats. Apply lubricant to the brake caliper guide pin threads.
2. If removed, install the upper brake caliper guide pin (1) and tighten to 61 N.m (45 lb ft).
3. If removed, install the lower brake caliper guide pin (2) and tighten to 61 N.m (45 lb ft).
4. Apply a light coat of high temperature silicone brake lubricant to the brake caliper guide bores and seals.
5. Install the brake caliper guide pin seals (1) and caps (2), if removed. Ensure the brake caliper guide pin seals and caps are fully seated in the grooves of the brake caliper housing.
6. Install the rear disc brake caliper (1) to the brake caliper bracket. Ensure the brake caliper guide pin seals are fully seated in the grooves of the brake caliper bracket.
7. Install the rear disc brake pads. Refer to «Rear Disc Brake Pads Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Disc Brake Pads Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .

1. J-41013 Rotor Resurfacing Kit
2. J-42450-A Wheel Hub Resurfacing Kit

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the front wheel hub extension, if equipped. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. Mark the relationship of the front wheel hub extension to the hub. Remove the front wheel hub extension bolts. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a non-metallic mallet to loosen it from the hub.
4. Mark the relationship of the rotor to the hub.
5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.
6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads.
7. Remove the C-clamp from the caliper.
8. Without disconnecting the hydraulic brake hose, remove the brake caliper bracket bolts and remove the brake caliper and bracket as an assembly and support with heavy mechanics wire or equivalent.
9. Remove the rotor retaining push nuts from the wheel studs, if applicable.
10. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub.
11. Remove the rotor.
12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only. Clean all the surface areas and the threaded holes of contamination. Generously apply penetrating oil or the equivalent to the hub/rotor area. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor. Tighten both bolts evenly to force the rotor from the hub.

1. Use the J-42450-A Wheel Hub Resurfacing Kit to clean all rust and contaminants from the mating surface of the hub flange.
2. Use the J-42450-A Wheel Hub Resurfacing Kit to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Align the rotor to its original position on the hub (if applicable) and install the rotor.
5. Install the caliper and caliper bracket assembly.
6. Prepare the brake caliper bracket bolts for installation: Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to 2/3 of the threaded portion of the bolt. Allow the threadlocket to cure approximately 10 minutes before installaton.
7. Install the caliper bracket bolts and tighten to 300 N.m (221 lb ft).
8. Install the front wheel hub extension, if equipped. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning. Align and install the front wheel hub extension to the original position on the hub. Following the wheel nut tightening sequence, install the front wheel hub extension nuts and tighten to 130 N.m (96 lb ft). Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
14. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

1. J-41013 Rotor Resurfacing Kit
2. J-42450-A Wheel Hub Resurfacing Kit

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
5. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
6. If installing the original brake rotor, mark the relationship of the brake rotor to the hub.
7. Compress the brake caliper pistons. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard brake pad. Slowly tighten the C-clamps until the caliper pistons are pushed completely into the caliper bores. Remove the C-clamps from the caliper.
8. Remove the 2 brake caliper bracket mounting bolts.
9. Remove the caliper and bracket assembly and support with heavy mechanics wire or equivalent.
10. Remove the brake rotor retaining push nuts from the wheel studs, if necessary.
11. Remove the brake rotor screw.
12. Install the wheel nuts on the wheel studs.
13. Using a deadblow hammer, strike the rotor between the wheel studs to separate the rotor from the wheel hub.
14. Remove the wheel nuts.
15. Remove the rotor.
16. If the brake rotor does not separate from the wheel hub, perform the following steps. Clean all the surface areas and the threaded holes of contamination. Generously apply penetrating oil or equivalent to the hub/rotor area. Insert 2 M10 x 1.5 bolts into the threaded holes of the rotor. Tighten the bolts evenly to force the rotor from the hub.

1. Using the J-42450-A Wheel Hub Resurfacing Kit, clean all rust and contaminants from the mating surface of the hub flange.
2. Using the J-41013 Rotor Resurfacing Kit, clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Align the rotor to its original position on the hub, if applicable, and install the rotor.
5. Install the brake rotor screw and tighten to 12 N.m (106 lb in).
6. Install the brake caliper and brake caliper bracket.
7. Perform the following procedure before installing the brake caliper bracket mounting bolts. Remove all traces of the original adhesive patch. Clean the threads of the bolts with brake parts cleaner or equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts.
8. Install the 2 brake caliper bracket mounting bolts and tighten to 175 N.m (129 lb ft).
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained to properly seat the caliper pistons and the brake pads.
13. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
14. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

1. J-2619-01 Slide Hammer with Adapter
2. J-41013 Rotor Resurfacing Kit
3. J-42450-A Wheel Hub Resurfacing Kit
4. J46277 Rotor Removal Tool

1. Release the park brake.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
4. Mark the relationship of the rotor to the hub.
5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.
6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads.
7. Remove the C-clamp from the caliper.
8. Remove the brake caliper bracket bolts.
9. Without disconnecting the hydraulic brake hose, remove the brake caliper and bracket as an assembly and support with heavy mechanics wire or equvalent.
10. Remove the rotor retaining push nuts from the wheel studs, if applicable.
11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub.
12. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it while pulling outward.
13. If the brake rotor cannot be removed, perform the following: Assemble the J46277 Rotor Removal Tool to the J-2619-01 Slide Hammer with Adapter. Insert the J46277 Rotor Removal Tool between the rotor friction surfaces in the vent section of the rotor. DO NOT place the J46277 Rotor Removal Tool on the rotor friction surface. Using the J46277 Rotor Removal Tool and the J-2619-01 Slide Hammer with Adapter, remove the rotor from the hub assembly. Inspect the park brake components for the following conditions: Bent or broken springs Broken, cracked or worn brake shoe lining Bent or damaged brake shoe Worn, bent or damaged backing plate Replace any damaged components.

1. Use the J-42450-A Wheel Hub Resurfacing Kit to clean all rust and contaminants from the mating surface of the hub flange.
2. Use the J-41013 Rotor Resurfacing Kit to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Align the rotor to its original position on the hub, if applicable, and install the rotor.
5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle.
6. Install the caliper and the bracket as an assembly to the vehicle.
7. Prepare the brake caliper bracket bolts for installation: Remove all traces of the original adhesive patch. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to 2/3 of the threaded portion of the bolt. Allow the threadlocket to cure approximately 10 minutes before installation.
8. Install the caliper bracket bolts and tighten to 200 N.m (148 lb ft).
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to «Master Cylinder Reservoir Filling»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
14. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the brake caliper bracket bolts (1).
4. Remove the brake caliper and bracket assembly (1) and support with heavy mechanics wire or equivalent.
5. Remove the rear axle shaft and hub. Refer to «Rear Axle Hub, Bearing, Cup, and/or Seal Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#rear-drive-axle) . It is not necessary to remove the bearings and cups from the hub unless replacement is required.
6. Remove the brake rotor and hub assembly (1) from the rear axle.
7. Mark the relationship of the hub to the rotor.
8. Using a hydraulic press, press the wheel studs (1) from the hub and rotor assembly.
9. Separate the hub (1) from the brake rotor.
10. Using a stiff brush, clean any loose debris and corrosion from the mating surfaces of the brake rotor and the rear axle hub.

1. Install the hub (1) to the brake rotor.
2. Install the rear axle hub to the brake rotor. Align the matchmarks on the rear axle hub to the brake rotor.
3. Using a hydraulic press, press the wheel studs (1) in the hub and rotor assembly.
4. Prepare the brake caliper bracket bolts and the rear axle threaded holes for assembly. Clean the brake caliper bracket bolts of any threadlocker residue Clean the rear axle threaded holes of any threadlocker residue with denatured alcohol and allow to dry
5. Apply threadlocker GM P/N 89021297 (Canadian P/N 10953488) to 2/3 of the threaded length of the brake caliper bracket bolt.
6. Allow the threadlocker to cure approximately 10 minutes before assembly.
7. Position the brake caliper and bracket assembly (1) to the rear axle.
8. Install the brake caliper bracket bolts (1) and tighten to 300 Y (221 lb ft).
9. Adjust the park brake, if necessary. Refer to «Parking Brake Adjustment (Without Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-adjustment-without-dual-rear) , «Parking Brake Adjustment (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-adjustment-with-dual-rear) .
10. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
11. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to «Brake Pad and Rotor Burnishing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-pad-and-rotor-burnishing) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
2. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the hub and bearing assembly (5). Refer to «Front Wheel Hub, Bearing, and Seal Replacement (4WD)»(/chevrolet/express-g2500/2013-2013/remont/suspension-front/#front-suspension-system__front-wheel-hub-bearing-and-seal) , «Front Wheel Hub, Bearing, and Seal Replacement (RWD)»(/chevrolet/express-g2500/2013-2013/remont/suspension-front/#front-suspension-system) .
4. Remove the splash shield (6), for 15 series.
5. Remove the splash shield, for 25/35 series.

1. Install the splash shield (6), for 15 series.
2. Install the splash shield, for 25/35 series.
3. Install the hub and bearing assembly (5). Refer to «Front Wheel Hub, Bearing, and Seal Replacement (4WD)»(/chevrolet/express-g2500/2013-2013/remont/suspension-front/#front-suspension-system__front-wheel-hub-bearing-and-seal) , «Front Wheel Hub, Bearing, and Seal Replacement (RWD)»(/chevrolet/express-g2500/2013-2013/remont/suspension-front/#front-suspension-system) .
4. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
5. Remove the safety stands.
6. Lower the vehicle.

Rear Brake Shield Replacement (JH5, JH6)

1. Disable the park brake cable automatic adjuster. Refer to «Parking Brake Cable Adjuster Disabling»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-cable-adjuster-disabling) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
4. Perform the following procedure to remove the cable (2) from the rear brake shield (4): Compress the spring (3) by pushing towards the lever (1). Depress the locking tabs. Pull the cable housing out of the rear brake shield (4). Remove the cable (2) through the slot in the rear brake shield.
5. Remove the park brake cable (2) from the lever (1).
6. For vehicles with semi-floating rear axles, perform the following steps: Remove the rotor. Refer to «Rear Brake Rotor Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Rotor Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) . Remove the axle shaft. Refer to «Rear Axle Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#rear-drive-axle) .
7. For vehicles with full-floating rear axles, perform the following steps: Remove the rotor. Refer to «Rear Brake Rotor Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Rotor Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) . Remove the hub assembly. Refer to «Rear Axle Hub, Bearing, Cup, and/or Seal Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#rear-drive-axle) .
8. Remove the park brake shoe. Refer to «Parking Brake Shoe Replacement (Single Rear Wheel - 1500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Single rear Wheel - 2500/3500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) .
9. Remove the rear brake shield nuts.
10. Remove the rear brake shield from the axle housing flange.

1. Install the rear brake shield to the axle housing flange.
2. Install the rear brake shield nuts and tighten to 135 N.m (100 lb ft).
3. Install the park brake shoe. Refer to «Parking Brake Shoe Replacement (Single Rear Wheel - 1500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Single rear Wheel - 2500/3500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) .
4. For vehicles with semi-floating rear axles, perform the following steps: Install the axle shaft. Refer to «Rear Axle Shaft Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#rear-drive-axle) . Install the rotor. Refer to «Rear Brake Rotor Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Rotor Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
5. For vehicles with full-floating rear axles, perform the following steps: Install the hub assembly. Refer to «Rear Axle Hub, Bearing, Cup, and/or Seal Replacement»(/chevrolet/express-g2500/2013-2013/remont/differentials-drive-axles/#rear-drive-axle) . Install the rotor. Refer to «Rear Brake Rotor Replacement (JH5, JH6)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) , «Rear Brake Rotor Replacement (JH9)»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system) .
6. Adjust the park brake shoe. Refer to «Parking Brake Adjustment (Without Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-adjustment-without-dual-rear) , «Parking Brake Adjustment (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-adjustment-with-dual-rear) .
7. Install the park brake cable (2) to the lever (1).
8. Perform the following procedure to install the cable (2) to the rear brake shield (4): Compress the spring (3) by pushing towards the lever (1). Route the cable (2) through the slot in the rear brake shield. Push the cable housing into the rear brake shield (4) until the locking tabs snap into place.
9. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
10. Enable the park brake cable automatic adjuster. Refer to «Parking Brake Cable Adjuster Enabling»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-cable-adjuster-enabling) .

1. Disable the parking brake cable adjuster. Refer to «Parking Brake Cable Adjuster Disabling»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-cable-adjuster-disabling) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/express-g2500/2013-2013/remont/hoistjack/#general-information) .
3. Remove the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
4. Remove the parking brake shoes. Refer to «Parking Brake Shoe Replacement (Single Rear Wheel - 1500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Single rear Wheel - 2500/3500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) .
5. Remove the parking brake actuator. Refer to «Parking Brake Actuator Replacement (Without Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Actuator Replacement (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) .
6. Remove the brake shield bolts (1).
7. Remove the brake shield (1).

1. Install the brake shield (1).
2. Install the brake shield bolts (1) and tighten to 10 N.m (89 lb in).
3. Install the parking brake actuator. Refer to «Parking Brake Actuator Replacement (Without Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Actuator Replacement (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) .
4. Install the parking brake shoes. Refer to «Parking Brake Shoe Replacement (Single Rear Wheel - 1500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Single rear Wheel - 2500/3500 Series)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) , «Parking Brake Shoe Replacement (Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system) .
5. Adjust the parking brake. Refer to «Parking Brake Adjustment (Without Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-adjustment-without-dual-rear) , «Parking Brake Adjustment (With Dual Rear Wheel)»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-adjustment-with-dual-rear) .
6. Install the tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
7. Enable the parking brake cable adjuster. Refer to «Parking Brake Cable Adjuster Enabling»(/chevrolet/express-g2500/2013-2013/remont/parking-brake-system/#parking-brake-system__parking-brake-cable-adjuster-enabling) .

Brake Rotor Assembled Lateral Runout Correction

Note. Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement . Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3, 000-7, 000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement .

Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired.

1. The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to «Brake Rotor Assembled Lateral Runout Correction - Indexing»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
2. The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to «Brake Rotor Assembled Lateral Runout Correction - Correction Plates»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
3. The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .

If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern.

Brake Rotor Assembled Lateral Runout Correction - Indexing

Note. This Procedure is not used in Europe

Special Tools

CH-45101-100 Conical Brake Rotor Washers

For equivalent regional tools, refer to Special Tools .

1. Remove the CH-45101-100 Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining.
3. Index the brake rotor in a different orientation to the hub/axle flange.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining CH-45101-100 Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern.
7. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
8. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-measurement) .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14.
11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 Conical Brake Rotor Washers and the lug nuts.

Brake Rotor Assembled Lateral Runout Correction - Correction Plates

Note. This procedure not used in Europe

Special Tools

CH-45101-100 Conical Brake Rotor Washers

For equivalent regional tools, refer to Special Tools .

1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward.
2. Remove the CH-45101-100 Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining.
4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used.
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward.
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
8. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud.
9. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
10. Install the remaining CH-45101-100 Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern.
11. Tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to «Tire and Wheel Removal and Installation (6-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) , «Tire and Wheel Removal and Installation (8-Lug Wheel)»(/chevrolet/express-g2500/2013-2013/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) .
12. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-measurement) .
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 Conical Brake Rotor Washers and the lug nuts.

Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe

Note. This procedure is not used in Europe.

Special Tools

CH-45101-100 Conical Brake Rotor Washers

For equivalent regional tools, refer to Special Tools .

1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor.
2. Remove the CH-45101-100 Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining.
4. Set up the lathe, following the manufacturer's instructions.
5. Refinish the brake rotor, following the brake lathe manufacturer's instructions.
6. After each successive cut, inspect the brake rotor thickness. Refer to «Brake Rotor Thickness Measurement»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-thickness-measurement) .
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10.
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. Using moderate pressure, apply the non-directional finish: If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner.
9. Remove the lathe from the vehicle.
10. Measure the assembled LRO of the brake rotor. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-measurement) .
11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .
12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 Conical Brake Rotor Washers and the lug nuts.

Brake Rotor Refinishing

Special Tools

1. CH-41013 Rotor Resurfacing Kit
2. CH-42450-A Wheel Hub Resurfacing Kit

For equivalent regional tools, refer to Special Tools .

Note. The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: Brake system noise - squeal, growl, groan Uneven and/or premature disc brake pad wear Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface Scoring of the disc brake rotor friction surface less than the maximum allowable specification Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement . Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: Thickness variation in excess of the maximum allowable specification Excessive corrosion/rust and/or pitting Cracks and/or heat spots Excessive blueing discoloration Scoring of the disc brake rotor surface in excess of the maximum allowable specification Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification.

Note. If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions.

1. Using the CH-42450-A Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
2. Using the CH-41013 Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris.
5. Ensure that any vibration dampening attachments are securely in place.
6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces.
7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe.
9. Following the brake lathe manufacturer's instructions, refinish the brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to «Brake Rotor Thickness Measurement»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-thickness-measurement) .
11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced.
12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. Using moderate pressure, apply the non-directional finish: If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. NOTE: Thoroughly cleaning the brake rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the brake pad material during the burnishing process, thereby reducing the possibility for brake squeal or other brake noises to occur. After applying a non-directional finish, clean each friction surface of the brake rotor with a solution of mild dish washing detergent and water, or a GM approved brake cleaner and a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles.
13. Remove the brake rotor from the brake lathe.
14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to «Brake Rotor Assembled Lateral Runout Measurement»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-measurement) .
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to «Brake Rotor Assembled Lateral Runout Correction»(/chevrolet/express-g2500/2013-2013/remont/mechanical-hydraulic/#disc-brake-system__brake-rotor-assembled-lateral-runout-correction) .

System Component Description

The disc brake system consists of the following components

System Operation

Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows the output force to be equally distributed. The brake pads apply the output force to the friction surfaces on both sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both the brake pad and brake caliper hardware is essential for even distribution of braking force.

Illustration Tool Number/Description J 2619-O1 Slide Hammer J 8001 Dial Indicator Set J 39544-KIT Torque-Limiting Socket Set J 41013 Rotor Resurfacing Kit J 42450-A Wheel Hub Resurfacing Kit J 45101 Hub and Wheel Runout Gauge J 45101-100 Conical Brake Rotor Washers J 46277 Rotor Removal Tool

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

See also:
• Brake Dust Warning
• Tire and Wheel Removal and Installation (6-Lug Wheel)
• Lifting and Jacking the Vehicle
• Brake Fluid Irritant Warning
• Master Cylinder Reservoir Filling
• Fastener Caution
• Hydraulic Brake System Bleeding (Pressure)
• Rear Axle Hub, Bearing, Cup, and/or Seal Replacement
• Parking Brake Adjustment (Without Dual Rear Wheel)
• Parking Brake Adjustment (With Dual Rear Wheel)
• Front Wheel Hub, Bearing, and Seal Replacement (4WD)
• Front Wheel Hub, Bearing, and Seal Replacement (RWD)
• Parking Brake Cable Adjuster Disabling
• Parking Brake Shoe Replacement (Single Rear Wheel - 1500 Series)
• Parking Brake Cable Adjuster Enabling
• Front Disc Brake Pads Replacement (JH6, JH9)
• Front Disc Brake Pads Replacement (JH5)
• Brake Rotor Thickness Variation Measurement
• Brake Rotor Refinishing
• Brake Rotor Assembled Lateral Runout Correction
• Front Brake Caliper Replacement (JH5)
• Brake Caliper Inspection
• Brake Pad and Rotor Burnishing
• Rear Disc Brake Mounting and Hardware Inspection (With Single Rear Wheel)
• Front Disc Brake Mounting and Hardware Inspection
• Rear Brake Caliper Bracket Replacement (JH5, JH6)
• Brake Rotor Assembled Lateral Runout Measurement
• Brake Rotor Thickness Measurement