Astro, Safari 1997-2005

Brake Disc (Rotor)

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Removal & Installation




CAUTION
Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

The following special tools may be required:



J 2619-01 Slide Hammer With Adapter
 
J 41013 Rotor Resurfacing Kit
 
J 42450-A Wheel Hub Resurfacing Kit
 
J-46277 Rotor Removal Tool
 

  1. Release the park brake.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Mark the relationship of the rotor to the hub.
  8.  
  9. Remove the brake caliper bracket mounting bolts.
    WARNING
    Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

  10.  
  11. Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.
  12.  
  13. Remove the rotor retaining push nuts from the wheel studs (if applicable).
  14.  
  15. 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.

    Click image to see an enlarged view

    Fig. View of rear brake rotor and hub

  16.  
  17. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward.
  18.  
  19. If the brake rotor cannot be removed perform the following:
    1. Assemble J-46277 to J 2619-01.
    2.  
    3. Insert J-46277 between the rotor friction surfaces in the vent section of the rotor. DO NOT place the J-46277 on the rotor friction surface.

      Click image to see an enlarged view

      Fig. Using a slide hammer to remove brake rotor

    4.  
    5. Using J-46277 and J 2619-01 remove the rotor from the hub assembly.
    6.  

  20.  
  21. Inspect the park brake components for the following conditions:
    1. Bent or broken hold down spring
    2.  
    3. Broken, cracked or worn brake shoe lining
    4.  
    5. Bent or damaged brake shoe
    6.  
    7. Worn, bent or damaged backing plate
    8.  

  22.  
  23. If any of these conditions are found replace the affected parts.
  24.  

To install:


NOTE
Whenever the brake rotor has been separated from the wheel bearing flange, clean any rust or foreign material from the mating surface of the rotor and flange with the J 42450 hub cleaning kit. Failure to do this may result in increased lateral run-out of the rotor and brake pulsation.

  1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange.
  2.  
  3. Use the J 41013 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.
  4.  
  5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle.
  6.  
  7. Install the caliper and the bracket as an assembly to the vehicle.
  8.  
  9. Perform the following procedure before installing the caliper bracket mounting bolts.
    1. Remove all traces of the original adhesive patch.
    2.  
    3. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
    4.  
    5. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) (or equivalent) to the threads of the bolt.
    6.  

  10.  
  11. Install the caliper bracket mounting bolts.
    1. Tighten the brake caliper bracket mounting bolts to 129 ft. lbs. (175 Nm).
    2.  

  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Lower the vehicle.
  16.  
  17. With the engine OFF , gradually apply the brake pedal to approximately 2 / 3 of it's travel distance.
  18.  
  19. Slowly release the brake pedal.
  20.  
  21. Wait 15 seconds, then reapply brakes until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  22.  
  23. Fill the master cylinder reservoir to the proper level with clean brake fluid.
  24.  

 
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