Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Brake Disc (Rotor)

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Removal & Installation



  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the front wheel hub extension (dual wheel vehicles only).
    1. 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.
    2.  
    3. Mark the relationship of the front wheel hub extension to the hub
    4.  
    5. Remove the front wheel hub extension bolts
    6.  
    7. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub
    8.  

  8.  
  9. Mark the relationship of the rotor to the hub.
  10.  
  11. Remove the caliper and mounting bracket as an assembly.
  12.  
  13. Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
  14.  
  15. Remove the rotor.
  16.  
  17. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (25 series only).
    1. Clean all the surface areas and the threaded holes of contamination
    2.  
    3. Generously apply penetrating oil or the equivalent to the hub/rotor area
    4.  
    5. Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor
    6.  
    7. Tighten both bolts evenly to force the rotor from the hub.

      Click image to see an enlarged view

      Fig. Front brake rotor and hub-typical

    8.  

  18.  

To install:

  1. Clean all rust and contaminants from the both side of the rotor and the hub flange.
    NOTE
    If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.

  2.  
  3. Install the rotor.
  4.  
  5. Install the caliper and the mounting bracket as an assembly.
  6.  
  7. Install the tire and wheel assembly.
  8.  
  9. Remove the safety stands.
  10.  
  11. Lower the vehicle.
  12.  

  1. Raise and properly support vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the brake rotor.
  8.  
  9. Remove the bolts that mount the front brake rotor to the hub.
  10.  
  11. Remove the brake rotor from the hub.

    Click image to see an enlarged view

    Fig. Bolts mount the front brake rotor to the hub

  12.  

To install:


WARNING
Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable.

  1. Install the brake rotor to the hub.
  2.  
  3. Install the bolts that mount the brake rotor to the hub, or the wheel.
    1. Tighten the brake rotor bolts (5/8 in OD-5 bolt pattern) to 189 ft. lbs. (256 Nm).
      NOTE
      Ensure that the threads are clean and greaseless before applying the thread locker.

    2.  

  4.  
  5. Apply 272 Thread locker GM P/N 12345493, or the equivalent, to the threads of each brake rotor bolt.
  6.  
  7. Install the brake rotor.
  8.  
  9. Inspect the brake rotor for run-out after installation.
  10.  
  11. Clean both sides of the brake rotor with Brake Parts Cleaner.
  12.  
  13. Clean the grease cap or cover.
  14.  
  15. Coat the inside of the grease cap with new wheel grease. Do not fill the cap.
  16.  
  17. Install the brake caliper.
  18.  
  19. Install the tire and wheel.
  20.  
  21. Lower the vehicle.
    CAUTION
    Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.


    NOTE
    Check the level of the brake fluid in the master cylinder reservoir after pumping the brake pedal.

  22.  
  23. Pump the brake pedal several times in order to ensure the pedal is firm and the brake pads are adjusted.
  24.  

  1. Block the wheels.
  2.  
  3. Apply the parking brake.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove the tire and wheel.
  8.  
  9. Remove the brake caliper.
  10.  
  11. Remove the brake rotor.

    Click image to see an enlarged view

    Fig. Removing rotor from the hub

  12.  
  13. Remove the bolts that mount the front brake rotor to the hub.
  14.  
  15. Remove the brake rotor from the hub.
  16.  

To install:


WARNING
Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable.

  1. Install the brake rotor to the hub.
  2.  
  3. Install the bolts that mount the brake rotor to the hub, or the wheel.
  4.  
  5. Tighten the brake rotor bolts (5/8 in OD-5 bolt pattern) to 189 ft. lbs. (256 Nm).
    NOTE
    Ensure that the threads are clean and greaseless before applying the threadlocker.

  6.  
  7. Apply 272 Threadlocker GM P/N 12345493, or the equivalent, to the threads of each brake rotor bolt.
  8.  
  9. Install the brake rotor.
  10.  
  11. Inspect the brake rotor for runout after installation.
  12.  
  13. Clean both sides of the brake rotor with Brake Parts Cleaner GM P/N 12345754 or the equivalent.
  14.  
  15. Clean the grease cap or cover.
  16.  
  17. Coat the inside of the grease cap with new wheel grease. Do not fill the cap.
  18.  
  19. Install the brake caliper.
  20.  
  21. Install the tire and wheel.
  22.  
  23. Lower the vehicle.
    CAUTION
    Do not move the vehicle until a firm brake pedal is obtained. Failure to obtain a firm pedal before moving vehicle may result in personal injury.


    NOTE
    Check the level of the brake fluid in the master cylinder reservoir after pumping the brake pedal.

  24.  
  25. Pump the brake pedal several times in order to ensure the pedal is firm and the brake pads are adjusted.
  26.  
  27. Remove the blocks.
  28.  

  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the front wheel hub extension (dual wheel vehicles only).
    1. 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.
    2.  
    3. Mark the relationship of the front wheel hub extension to the hub
    4.  
    5. Remove the front wheel hub extension bolts
    6.  
    7. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub
    8.  

  8.  
  9. Mark the relationship of the rotor to the hub.
  10.  
  11. Remove the caliper and mounting bracket as an assembly.
  12.  
  13. Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
  14.  
  15. If equipped with dual rear wheels, remove the hub extension.

    Click image to see an enlarged view

    Fig. Hub extension on dual rear wheel models

  16.  
  17. Remove the rotor. Remove the rotor screw first, if equipped.
  18.  
  19. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (2500 series only).
    1. Clean all the surface areas and the threaded holes of contamination
    2.  
    3. Generously apply penetrating oil or the equivalent to the hub/rotor area
    4.  
    5. Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor
    6.  
    7. Tighten both bolts evenly to force the rotor from the hub.

      Click image to see an enlarged view

      Fig. Front brake rotor and hub-6 bolt hubs



      Click image to see an enlarged view

      Fig. Front brake rotor and hub-8 bolt hubs

    8.  

  20.  

To install:

  1. Clean all rust and contaminants from the both side of the rotor and the hub flange.
    NOTE
    If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.

  2.  
  3. Install the rotor.
  4.  
  5. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry.
  6.  
  7. Install the caliper and the mounting bracket as an assembly. Apply Red Loctite® #272 to the threads of the bolt. On 2005-06 Avalanche, tighten the bolts to 133 ft. lbs. (180 Nm) on 6 bolt hubs and 221 ft. lbs. (300 Nm) on 8 bolt hubs. On other models, tighten them to 129 ft. lbs. (175 Nm) on 6 bolt hubs and 221 ft. lbs. (300 Nm) on 8 bolt hubs.
  8.  
  9. Install the hub extension on dual rear wheel models. Tighten the bolts to 96 ft. lbs. (130 Nm).
  10.  
  11. Install the tire and wheel assembly.
  12.  
  13. Remove the safety stands.
  14.  
  15. Lower the vehicle.
  16.  

  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the front wheel hub extension (dual wheel vehicles only).
    1. 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.
    2.  
    3. Mark the relationship of the front wheel hub extension to the hub
    4.  
    5. Remove the front wheel hub extension bolts
    6.  
    7. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub
    8.  

  8.  
  9. Mark the relationship of the rotor to the hub.
  10.  
  11. Remove the caliper and mounting bracket as an assembly.
  12.  
  13. Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
  14.  
  15. If equipped with dual rear wheels, remove the hub extension.

    Click image to see an enlarged view

    Fig. Hub extesnion on dual rear wheel models

  16.  
  17. Remove the rotor. Remove the rotor screw first, if equipped.
  18.  
  19. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (2500 series only).
    1. Clean all the surface areas and the threaded holes of contamination
    2.  
    3. Generously apply penetrating oil or the equivalent to the hub/rotor area
    4.  
    5. Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor
    6.  
    7. Tighten both bolts evenly to force the rotor from the hub.

      Click image to see an enlarged view

      Fig. Front brake rotor and hub-2005-06 models and 2007 Classic



      Click image to see an enlarged view

      Fig. Front brake rotor and hub-2007 models, except Classic with 6 bolt hubs



      Click image to see an enlarged view

      Fig. Front brake rotor and hub-2007 models, except Classic with 8 bolt hubs

    8.  

  20.  

To install:

  1. Clean all rust and contaminants from the both side of the rotor and the hub flange.
    NOTE
    If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.

  2.  
  3. Install the rotor.
  4.  
  5. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry.
  6.  
  7. Install the caliper and the mounting bracket as an assembly. Apply Red Loctite® #272 to the threads of the bolt. On 2005-06 models and 2007 Classic, tighten the bolts to 133 ft. lbs. (180 Nm) on 6 bolt hubs and 221 ft. lbs. (300 Nm) on 8 bolt hubs. On 2007 models except Classic, tighten them to 129 ft. lbs. (175 Nm) on 6 bolt hubs and 221 ft. lbs. (300 Nm) on 8 bolt hubs.
  8.  
  9. Install the hub extension on dual rear wheel models. Tighten the bolts to 96 ft. lbs. (130 Nm).
  10.  
  11. Install the tire and wheel assembly.
  12.  
  13. Remove the safety stands.
  14.  
  15. Lower the vehicle.
  16.  

Models Above 8600 GVW
  1. Raise and properly support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the nut.
  8.  
  9. Remove the hub/rotor mounting bolts.

    Click image to see an enlarged view

    Fig. Hub to rotor mounting bolts

  10.  
  11. Remove the rotor assembly.
  12.  
  13. Inspect all of the parts. Replace the parts as necessary.

    Click image to see an enlarged view

    Fig. Front brake rotor assembly-exploded view

  14.  

To install:

  1. Install the hub/rotor to the hub and bearing assembly.
  2.  
  3. Install the rotor and hub assembly to the axle.
    1. Tighten the bolts to 133 ft. lbs. (180 Nm).
    2.  
    3. Tighten the nut to 165 ft. lbs. (225 Nm).
    4.  

  4.  
  5. Install the brake caliper.
  6.  
  7. Install the tire and wheel assembly.
  8.  
  9. Lower the vehicle.
  10.  
  11. Depress the brake pedal to seat the brake pads.
  12.  

  1. Raise the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the nut.
  8.  
  9. Remove the hub/rotor retaining bolts.
  10.  
  11. Remove the rotor assembly.
  12.  
  13. Inspect all of the parts. Replace the parts as necessary.
  14.  

To install:

  1. Install the hub/rotor to the hub and bearing assembly.
  2.  
  3. Install the rotor and hub assembly to the axle.
  4.  
  5. Tighten the bolts to 133 ft. lbs. (180 Nm).
  6.  
  7. Tighten the nut to 165 ft. lbs. (225 Nm).
  8.  
  9. Install the brake caliper.
  10.  
  11. Install the tire and wheel.
  12.  
  13. Lower the vehicle.
  14.  
  15. Depress the brake pedal.
  16.  

Models Below 8600 GVW
  1. Raise the vehicle. Support the vehicle with suitable safety stands.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the rotor.
  8.  
  9. Inspect all of the parts. Replace the parts as necessary.

    Click image to see an enlarged view

    Fig. Front brake rotor assembly-exploded view

  10.  

To install:

  1. Install the rotor to the hub and bearing assembly.
  2.  
  3. Install the brake caliper.
  4.  
  5. Install the tire and wheel assembly.
  6.  
  7. Lower the vehicle.
  8.  
  9. Depress the brake pedal to seat the brake pads
  10.  

  1. Raise the vehicle. Support the vehicle with suitable safety stands.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the rotor.
  8.  
  9. Inspect all of the parts. Replace the parts as necessary.
  10.  

To install:

  1. Install the rotor to the hub and bearing assembly.
  2.  
  3. Install the brake caliper.
  4.  
  5. Install the tire and wheel.
  6.  
  7. Lower the vehicle.
  8.  
  9. Depress the brake pedal.
  10.  

 
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