Express, Savana, G1500, G2500, G3500, 1998-2005

Brake Caliper

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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.


NOTE
There are 2 caliper designs and they can be identified by the method used to secure the assembly to the spindle bracket. The Delco caliper is secured by a bolt and sleeve combination. The Bendix caliper assembly is secured by a slider, spring and bolt.

  1. Remove or disconnect the following:

    2 / 3 of the brake fluid from the master cylinder
     
    Tire and wheel assembly
     

  2.  
  3. Using a C-clamp or the equivalent, compress the caliper piston until the caliper piston bottoms in the bore.

    Brake hose at caliper by removing the inlet fitting bolt. Plug the line.
     
    Bolt and sleeve or bolt and slider assemblies that hold the caliper and then lift the caliper off the rotor
     

  4.  
  5. Inspect the caliper assembly.

    Click image to see an enlarged view

    Fig. Compressing the caliper piston-Express & Savana

  6.  

To install:

  1. Install or connect the following:

    Caliper onto the knuckle/rotor assembly and secure the assembly with the mounting bolts or sliders. Tighten the front bolts to 80 ft. lbs. (108 Nm). Tighten the rear bolts to 31 ft. lbs. ( 30 Nm) on 15 series and 80 ft. lbs. (108 Nm) on 25/35 series.
     
    Brake line to the caliper
     

  2.  
  3. Bleed the brakes.
  4.  
  5. Pump the brake pedal and verify there is minimal brake pedal travel.
  6.  
  7. Check the brake fluid level. Install the tire and wheel assembly.
  8.  

  1. Remove or disconnect the following:

    2 / 3 of the brake fluid from the master cylinder
     
    Tire and wheel assembly
     

  2.  
  3. Using a C-clamp or the equivalent, compress the caliper piston until the caliper piston bottoms in the bore.

    Brake hose at caliper by removing the inlet fitting bolt. Plug the line.
     
    Caliper mounting bolts
     
    Caliper
     

  4.  
  5. Inspect the caliper assembly.

    Click image to see an enlarged view

    Fig. Front caliper removal-6 bolt hubs



    Click image to see an enlarged view

    Fig. Front caliper removal-8 bolt hubs

  6.  

To install:

  1. Install or connect the following:

    Caliper. Tighten the caliper guide pin bolts to 74 ft. lbs. (100 Nm) on 1500 series or 80 ft. lbs. (108 Nm) on 2500 series.
     
    Brake hose at caliper by installing the inlet fitting bolt. Tighten the inlet fitting bolt to 30 ft. lbs. (40 Nm).
     

  2.  
  3. Bleed the brakes.

    Tire and wheel assembly
     

  4.  

 
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