Rear Brake Caliper Replacement 1500 Series w/o NYS

Caution: Refer to Brake Dust Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding.
4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Compress the brake caliper piston.

5.1.	Install a C-clamp over the top of the caliper housing and against the back of the outboard pad.

5.2.	Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.

5.3.	Remove the C-clamp from the caliper.




6. Clean all dirt and foreign material from the brake hose fitting.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.

7. Remove the brake hose to caliper bolt.
8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or the brake hose end.
9. Remove the brake hose from the caliper.



10. Remove the brake caliper bolts.



11. Remove the caliper from the caliper bracket.

Important: Use denatured alcohol to clean the outside surface of caliper boot before installing new brake pads.

1. If installing NEW brake pads, use a C-clamp in order to compress the piston to the bottom of the caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order to protect the piston and the caliper boot.




Important: Use a small flat-bladed tool and lift the inner edge caliper boot next to the piston to release any trapped air.

2. Ensure that the piston boot is below the level of the piston face.



3. Install the caliper to the caliper bracket.



4. Perform the following procedure before installing the brake caliper bolts.

4.1.	Remove all traces of the original adhesive patch.

4.2.	Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.

4.3.	Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.

Notice: Refer to Fastener Notice in the Preface section.

5. Install the brake caliper bolts.

Tighten
Tighten the bolts to 42 N·m (31 lb ft).




6. Remove the rubber cap or plug from the exposed brake hose fitting end.

Important: Install 2 NEW copper brake hose gaskets.

7. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose.
8. Install the brake hose to caliper bolt.

Tighten
Tighten the bolt to 40 N·m (30 lb ft).

9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.

Rear Brake Caliper Replacement 1500 Series w/NYS, 25/3500 Series

Caution: Refer to Brake Dust Caution in the Preface section.

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the fluid level is midway between the maximum - full point, and the minimum allowable level, no fluid needs to be removed from the reservoir before proceeding.
3. If the fluid level is higher than midway between the maximum - full point, and the minimum allowable level, remove fluid to the midway point before proceeding.
4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Compress the brake caliper pistons.

5.1.	Install a large C-clamp over the body of the top of the caliper housing and against the back of the outboard pad.

5.2.	Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.

5.3.	Remove the C-clamp from the caliper.




6. Clean all dirt and foreign material from the brake hose fitting.

Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.

7. Remove the brake hose to caliper bolt.
8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the caliper or brake hose end.
9. Remove the brake hose from the caliper.
10. Loosen the brake caliper bolts. DO NOT remove.



11. Remove the brake caliper bracket bolts.

Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.

12. Remove the caliper and caliper bracket as an assembly.
13. Remove the brake caliper bolts.
14. Remove the caliper from the caliper bracket.
15. Inspect the caliper. Refer to Brake Caliper Inspection .



16. Remove the brake pads from the caliper bracket.
17. Remove the anti-rattle clips.
18. Inspect the caliper bracket for cracks and/or damage. Replace if necessary.
19. Inspect the caliper bracket bushings for damage and/or wear. Replace the bushings if necessary.
20. Perform the following procedure to replace the brake caliper bracket bushings.

20.1.

Insert a flat-bladed tool between the bushing flange and the bracket.

20.2.

Work the tool around the bushing flange and remove the bushing from the bracket.

20.3.

Place a socket over the boot onto the bushing flange and install the bushing to the bracket.

1. Install the anti-rattle clips to the caliper bracket.
2. Install the brake pads.
3. Install the caliper to the caliper bracket.
4. Perform the following procedure before installing the caliper bracket bolts and the caliper bolts:

4.1.	Remove all traces of the original adhesive patch.

4.2.	Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.

4.3.	Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.

5. Install the brake caliper bolts. DO NOT tighten.



6. Install the caliper and caliper bracket as an assembly.

Notice: Refer to Fastener Notice in the Preface section.

7. Install the brake caliper bracket bolts.

Tighten
Tighten the bolts to 300 N·m (221 lb ft).

8. Tighten the brake caliper bolts.

Tighten
Tighten the bolts to 108 N·m (80 lb ft).




9. Remove the rubber cap or plug from the exposed brake hose fitting end.

Important: Install 2 NEW copper brake hose gaskets.

10. Assemble the 2 NEW copper brake hose gaskets to the brake hose bolt and brake hose.
11. Install the brake hose to caliper bolt.

Tighten
Tighten the bolt to 40 N·m (30 lb ft).

12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
14. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.