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

Brake Disc (Rotor)

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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.

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.  

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.  

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.  

 
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