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

Brake Pads

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Removal & Installation





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Fig. Front pad removal-6 bolt hubs



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Fig. Front pad removal-8 bolt hubs

  1. Remove 2 / 3 of the brake fluid from the master cylinder.
  2.  
  3. Remove or disconnect the following:

    Wheel
     

  4.  
  5. Using a C-clamp or the equivalent, compress the caliper piston until the caliper piston bottoms in the bore.
    NOTE
    On most models, complete removal of the caliper is not necessary. Remove one caliper guide pin bolt and rotate the caliper upwards.



    Caliper. Suspend the caliper from the frame with mechanic's wire. Do not allow the caliper to hang from the brake hose.
     
    Brake pads from the caliper mounting bracket
     
    Clips from the inside ends of the caliper mounting bracket and discard

    Click image to see an enlarged view

    Fig. Use a C-clamp to compress the piston in its bore

     

  6.  

To install:

  1. Install or connect the following:

    Clips to the inside ends of the caliper mounting bracket
     
    Brake pads to the caliper mounting bracket
     
    Caliper. Tighten to 74 ft. lbs. (100 Nm) on 6 bolt hubs or 80 ft. lbs. (108 Nm) on 8 bolt hubs.
     
    Tire and wheel assembly
     

  2.  
  3. Refill the master cylinder to the proper level with fresh brake fluid. Pump the brake pedal slowly and firmly in order to seat the brake pads. Burnish the brakes as needed.
  4.  

Bendix Type

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 or disconnect the following:

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

  2.  
  3. Compress the brake piston back into its bore using a C-clamp.

    Bolt at the caliper slider. Use a brass drift pin to remove the slider and spring.
     
    Caliper up and forward from the bottom and lift it off the caliper support. Tie the caliper out of the way with a piece of wire. Be careful not to damage the brake line.
     
    Inner shoe from the caliper support. Discard the inner shoe clip.
     
    Outer shoe from the caliper

    Click image to see an enlarged view

    Fig. Replacing the disc brake pads-Bendix type

     

  4.  

To install:

  1. Thoroughly clean, inspect and lubricate the caliper, slider and spring with silicone.
  2.  
  3. Install or connect the following:

    New inboard shoe clip on the shoe
     
    Lower end of the inboard shoe into the groove provided in the support. Slide the upper end of the shoe into position. Be sure the clip remains in position.
     
    Outboard shoe in the caliper, with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the caliper cutout. If assembly is difficult, a C-clamp may be used. Be careful not to damage the lining.
     
    Caliper over the brake disc, top edge first. Rotate the caliper downward onto the support.
     
    Spring over the caliper support key, install the assembly between the support and lower caliper groove. Tap into place until the key retaining screw can be installed.
     
    Screw and torque to 15 ft. lbs. (20 Nm). The boss must fit fully into the circular cutout in the key.
     

  4.  
  5. Install the wheel and add brake fluid as necessary.
  6.  

  1. Remove approximately 1 / 3 of the brake fluid from the master cylinder. Discard the used brake fluid.
  2.  
  3. Raise and support the vehicle safely and remove the wheel.
  4.  
  5. Push the piston back into its bore. This can be done by using a C-clamp.
  6.  
  7. Remove the bolt at the caliper slider. Use a brass drift pin to remove the slider and spring.
  8.  
  9. Rotate the caliper up and forward from the bottom and lift it off the caliper support.
  10.  
  11. Tie the caliper out of the way with a piece of wire. Be careful not to damage the brake line.
  12.  
  13. Remove the inner shoe from the caliper support. Discard the inner shoe clip.
  14.  
  15. Remove the outer shoe from the caliper.
  16.  

To install:

  1. Thoroughly clean, inspect and lubricate the caliper, slider and spring with silicone.
  2.  
  3. Install a new inboard shoe clip on the shoe.
  4.  
  5. Install the lower end of the inboard shoe into the groove provided in the support. Slide the upper end of the shoe into position. Be sure the clip remains in position.
  6.  
  7. Position the outboard shoe in the caliper, with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the caliper cutout. If assembly is difficult, a C-clamp may be used. Be careful not to damage the lining.
  8.  
  9. Position the caliper over the brake disc, top edge first. Rotate the caliper downward onto the support.
  10.  
  11. Place the spring over the caliper support key, install the assembly between the support and lower caliper groove. Tap into place until the key retaining screw can be installed.
  12.  
  13. Install the screw and torque to 15 ft. lbs. (20 Nm). The boss must fit fully into the circular cutout in the key.
  14.  
  15. Install the wheel and add brake fluid as necessary.

    Click image to see an enlarged view

    Fig. Replacing the disc brake pads-Bendix type

  16.  

Delco Type

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 or disconnect the following:

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

  2.  
  3. Compress the brake piston back into its bore using a C-clamp.

    2 bolts holding the caliper and then lift the caliper off the disc
     
    Inboard and outboard pads
     
    Pad support spring from the piston, if equipped

    Click image to see an enlarged view

    Fig. Replacing the disc brake pads-Delco type

     

  4.  

To install:

  1. Thoroughly inspect, clean and lubricate all caliper slide points, bolts and hardware.
  2.  
  3. Install or connect the following:

    Retainer spring on the inner pad and insert the assembly into the center cavity of the piston
     

  4.  
  5. Push down on the inner pad until it lays flat against the caliper. It is important to push the piston all the way into the caliper if new linings are installed or the caliper will not fit over the rotor.

    Outboard pad with the ears of the pad over the caliper ears and the tab at the bottom engaged in the caliper cutout
     
    Caliper over the brake disc and align the holes in the caliper with those of the mounting bracket
     
    Mounting bracket bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure the ends of the bolts pass under the retaining ears on the inboard pad
     
    Mounting bolts to 80 ft. lbs. (108 Nm). After both calipers are mounted pump the brake pedal to seat the pad against the rotor. Use a pair of locking pliers to bend over the upper ears of the outer pad so it isn't loose.
     
    Wheels
     

  6.  
  7. Add fluid to the master cylinder reservoirs so they are 1 / 4 in. (6.35mm) from the top.
  8.  
  9. Test the brake pedal by pumping it to obtain a hard pedal. Check the fluid level again and add fluid as necessary. Do not move the vehicle until a pedal is obtained.
  10.  

  1. Remove the cover on the master cylinder and siphon out 2 / 3 of the fluid. This step prevents spilling fluid when the piston is pushed back into the caliper bore.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the wheels.
  6.  
  7. Compress the brake piston back into its bore using a C-clamp.
  8.  
  9. Remove the 2 bolts holding the caliper and then lift the caliper off the disc.
  10.  
  11. Remove the inboard and outboard shoe.
  12.  
  13. Remove the pad support spring from the piston, if equipped.
  14.  

To install:

  1. Thoroughly inspect, clean and lubricate all caliper slide points, bolts and hardware.
  2.  
  3. Position the retainer spring on the inner pad and insert the assembly into the center cavity of the piston.
  4.  
  5. Push down on the inner pad until it lays flat against the caliper. It is important to push the piston all the way into the caliper if new linings are installed or the caliper will not fit over the rotor.
  6.  
  7. Position the outboard pad with the ears of the pad over the caliper ears and the tab at the bottom engaged in the caliper cutout.
  8.  
  9. With the 2 pads in position, place the caliper over the brake disc and align the holes in the caliper with those of the mounting bracket.
  10.  
  11. Install the mounting bracket bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure the ends of the bolts pass under the retaining ears on the inboard pad.
  12.  
  13. Tighten the mounting bolts to 38 ft. lbs. (51 Nm). After both calipers are mounted pump the brake pedal to seat the pad against the rotor. Use a pair of channel lock pliers to bend over the upper ears of the outer pad so it isn't loose.
  14.  
  15. Install the wheels and lower the vehicle.
  16.  
  17. Add fluid to the master cylinder reservoirs so they are 1 / 4 in. (6.35mm) from the top.
  18.  
  19. Test the brake pedal by pumping it to obtain a hard pedal. Check the fluid level again and add fluid as necessary. Do not move the vehicle until a pedal is obtained.

    Click image to see an enlarged view

    Fig. Replacing the disc brake pads-Delco type

  20.  

 
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