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

Brake Disc (Rotor)

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Removal & Installation



The brake rotor can be removed without separating the caliper from the mounting bracket.

  1. Release the parking brake.
  2.  
  3. Remove 2 / 3 of the brake fluid from the master cylinder.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the tire and wheel assembly.
  8.  
  9. Remove the caliper and mounting bracket as an assembly.
  10.  
  11. Hang the caliper and mounting bracket assembly from the suspension using mechanics wire.
  12.  
  13. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (15 series).
  14.  
  15. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (25 series).
    NOTE
    If the rotor is stuck to the hub, try using a slide hammer to free it.

  16.  

To install:


WARNING
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral run-out (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (15 series).
  8.  
  9. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (25 series).
  10.  
  11. Install the caliper and the mounting bracket as an assembly.
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Lower the vehicle.
  16.  

  1. Raise and properly support the vehicle.
  2.  
  3. Remove the tire and wheel.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the brake rotor (with the hub).
  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. The rear brake rotor is bolted to the wheel 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.
    1. Tighten the brake rotor bolts (9/16 in OD-10 bolt pattern) to 112 ft. lbs. (152 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 (with the hub).
  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 cover 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.  

Dual Rear Wheels
  1. Release the parking brake.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the hub and rotor assembly.
  8.  
  9. Mark the relationship of the hub to the rotor.
  10.  
  11. Place the hub and rotor assembly on a hydraulic press.
  12.  
  13. Press the wheel studs out of the hub and rotor assembly.
  14.  

To install:

  1. Align the hub and the rotor, if applicable.
  2.  
  3. Press the wheel studs into the hub and rotor assembly.
  4.  
  5. Install the hub and rotor assembly.
  6.  
  7. Install the tire and wheel assembly.
  8.  
  9. Lower the vehicle.
  10.  
  11. With the engine OFF , gradually apply the brake pedal to approximately 2 / 3 of it's travel distance.
  12.  
  13. Slowly release the brake pedal.
  14.  
  15. Wait 15 seconds, then repeat steps 5-6 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  16.  
  17. Fill the master cylinder reservoir to the proper level with clean brake fluid.
  18.  

  1. Release the parking brake.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the hub and rotor assembly.
  8.  
  9. Mark the relationship of the hub to the rotor.
  10.  
  11. Place the hub and rotor assembly on a hydraulic press.
  12.  
  13. Press the wheel studs out of the hub and rotor assembly.
  14.  

To install:

  1. Align the hub and the rotor, if applicable.
  2.  
  3. Press the wheel studs into the hub and rotor assembly.
  4.  
  5. Install the hub and rotor assembly.
  6.  
  7. Install the tire and wheel assembly.
  8.  
  9. Lower the vehicle.
  10.  
  11. With the engine OFF , gradually apply the brake pedal to approximately 2 / 3 of it's travel distance.
  12.  
  13. Slowly release the brake pedal.
  14.  
  15. Wait 15 seconds, then repeat steps 5-6 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  16.  
  17. Fill the master cylinder reservoir to the proper level with clean brake fluid.
  18.  

Single Rear Wheel

The brake rotor can be removed without separating the caliper from the mounting bracket.

  1. Release the parking brake.
  2.  
  3. Remove 2 / 3 of the brake fluid from the master cylinder.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the tire and wheel assembly.
  8.  
  9. Remove the caliper and mounting bracket as an assembly.
  10.  
  11. Hang the caliper and mounting bracket assembly from the suspension using mechanics wire.
  12.  
  13. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle.
    NOTE
    If the rotor is stuck to the hub, try using a slide hammer to free it.

  14.  

To install:


WARNING
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled Lateral Run-Out (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the rotor. Slowly turn the rotor while pushing the rotor toward the axle.
  8.  
  9. Install the caliper and the mounting bracket as an assembly.
  10.  
  11. Install the tire and wheel assembly.
  12.  
  13. Lower the vehicle.
  14.  

The brake rotor can be removed without separating the caliper from the mounting bracket.

  1. Release the parking brake.
  2.  
  3. Remove 2 / 3 of the brake fluid from the master cylinder.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the tire and wheel assembly.
  8.  
  9. Remove the caliper and mounting bracket as an assembly.
  10.  
  11. Hang the caliper and mounting bracket assembly from the suspension using mechanics wire.
  12.  
  13. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle.
    NOTE
    If the rotor is stuck to the hub, try using a slide hammer to free it.

  14.  

To install:


WARNING
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral run-out (LRO) of the brake rotor, which could lead to brake pulsation.

  1. Thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
  2.  
  3. Thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
  4.  
  5. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  6.  
  7. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle.
  8.  
  9. Install the caliper and the mounting bracket as an assembly.
  10.  
  11. Install the tire and wheel assembly.
  12.  
  13. Lower the vehicle.
  14.  

 
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