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

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. 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.  

Integral Hub & Rotor

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.

  1. Remove about 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and properly support the vehicle.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Remove the brake caliper from the spindle and support with mechanics wire.
    1. It is not necessary to open the hydraulic circuit by removing the brake hose unless the caliper is being serviced as well.
      WARNING
      Do not let the caliper hang by the brake hose. The unsupported weight of the brake caliper can damage the brake hose. Always use a piece of wire to hang the caliper whenever it is disconnected from the spindle.

    2.  

  8.  
  9. Remove the wheel bearings.
  10.  
  11. Remove the rotor from the vehicle.
  12.  
  13. Inspect and clean all of the parts. Replace any parts as necessary.
  14.  
  15. Refinish the rotor if required.

    Click image to see an enlarged view

    Fig. Brake rotor and spindle

  16.  
  17. Install the rotor to the vehicle.
  18.  
  19. Install the wheel bearings and seal.
  20.  
  21. Install the brake caliper.
  22.  
  23. If the hydraulic brake circuit was opened bleed the brake system.
  24.  
  25. Install the tire and wheel assembly.
  26.  
  27. Lower the vehicle.
  28.  
  29. Top off the brake fluid.
  30.  
  31. Depress the brake pedal to seat the pads to the rotor.
  32.  
  33. Top off the brake fluid again.
  34.  
  35. Road test the vehicle
  36.  

Separate Hub & Rotor

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.

  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Raise and properly 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.  

 
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