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

Tools Required

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

1. Release the park brake, if necessary.
2. Inspect the fluid level in the brake master cylinder reservoir.
3. 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.
4. 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.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Mark the relationship of the rotor to the hub.
7. Compress the brake caliper pistons.

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

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

7.3.	Remove the C-clamp from the caliper.

Notice: Refer to Brake Caliper Notice in the Preface section.




8. Remove the brake caliper bracket bolts.
9. Remove the caliper and caliper bracket as an assembly.

Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.




10. Remove the brake rotor retaining push nuts from the wheel studs, if applicable.
11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub.
12. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle.

Important: 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 runout (LRO) of the brake rotor, which could lead to brake pulsation.

1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange.
2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Align the rotor to its original position on the hub, if applicable.



5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle.
6. If the rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement .
7. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction .



8. Install the caliper and caliper bracket as an assembly.
9. Perform the following procedure before installing the brake caliper bracket bolts.

9.1.	Remove all traces of the original adhesive patch.

9.2.	Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry.

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

Notice: Refer to Fastener Notice in the Preface section.

10. Install the brake caliper bracket bolts.

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

11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Lower the vehicle.
13. With the engine OFF gradually apply the brake pedal to approximately 2/3 of its travel distance.
14. Slowly release the brake pedal.
15. Wait 15 seconds then repeat steps 15-16 until a firm pedal is obtained. This will properly seat the caliper pistons and pads.
16. 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 Rotor Replacement 1500 Series w/o NYS

Tools Required

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

1. Release the park brake, if necessary.
2. Inspect the fluid level in the brake master cylinder reservoir.
3. 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.
4. 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.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Mark the relationship of the rotor to the hub.
7. Compress the brake caliper pistons.

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

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

7.3.	Remove the C-clamp from the caliper.




8. Remove the brake caliper bracket bolts.

Notice: Refer to Brake Caliper Notice in the Preface section.




9. Remove the caliper and caliper bracket as an assembly.

Support the caliper with heavy mechanic's wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.




10. Remove the brake rotor retaining push nuts from the wheel studs, if applicable.
11. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub.
12. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle.



13. If the brake rotor cannot be removed, perform the following:

13.1.

Assemble J-46277 to J 2619-01 .

13.2.

Insert J-46277 between the rotor friction surfaces in the vent section of the rotor.

DO NOT place the J-46277 on the rotor friction surface.

13.3.

Using J-46277 andJ 2619-01 remove the rotor from the hub.

13.4.

Inspect the park brake components for the following conditions:

•	Bent or broken hold down spring

•	Broken, cracked or worn brake shoe lining

•	Bent or damaged brake shoe

•	Worn, bent or damaged back plate

13.5.

If any of these conditions are found replace the affected parts.

Important: 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 runout (LRO) of the brake rotor, which could lead to brake pulsation.

1. Use the J 42450-A to clean all rust and contaminants from the mating surface of the hub flange.
2. Use the J 41013 to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
4. Align the rotor to its original position on the hub, if applicable, and install the rotor.
5. If the rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement .
6. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction .



7. Install the brake rotor by slowly turning the rotor while pushing the rotor towards the axle.



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



9. Perform the following procedure before installing the caliper bracket bolts.

9.1.	Remove all traces of the original adhesive patch.

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

9.3.	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.

10. Install the brake caliper bracket bolts.

Tighten
Tighten the bolts to 200 N·m (148 lb ft).

11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
13. Slowly release the brake pedal.
14. Wait 15 seconds, then repeat steps 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads.
15. 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 Rotor Replacement 25/3500 Series w/Dual Wheels

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

1. Release the park brake, if necessary.
2. Remove the hub and rotor assembly. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement in Rear Drive Axle.
3. Mark the relationship of the hub to the rotor.
4. Place the hub and rotor on a hydraulic press.
5. Press the wheel studs out of the hub and rotor.

1. Align the hub and the rotor (if applicable).
2. Install each of the new wheel studs into the hub and rotor by performing the following steps:

2.1.	Install the stud.

2.2.	Install 4 washers to the stud.

2.3.	Install a lug nut to the stud with the flat side of the nut towards the washers.

2.4.	Tighten the lug nut to draw the stud into the hub and rotor.

2.5.	Inspect the hub and rotor to ensure that the hub is tight against the rotor and the stud is seated completely.

2.6.	Remove the lug nut and the washers.

3. Install the hub and rotor assembly to the vehicle. Refer to Rear Axle Hub, Bearing, Cup, and/or Seal Replacement in Rear Drive Axle.
4. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
5. Slowly release the brake pedal.
6. Wait 15 seconds, then repeat steps 6-7 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
7. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.