Front Brake Rotor Replacement 6500, 7500, 8500, FM8

Tools Required

Removal Procedure

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

1. Block the wheels.
2. Apply the parking brake.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .

Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

5. Remove the brake caliper. Refer to Front Brake Caliper Replacement .
6. Do not remove the brake line from the caliper.



7. Remove the brake rotor with the hub or with the wheel. Refer to Front Wheel Hub, Bearing, and Seal Replacement .



8. Remove the wheel speed sensor ring using the J 45107 .



9. Remove the bolts that mount the front brake rotor to the hub or the wheel using the J 44959 .
10. Remove the brake rotor from the hub, or the wheel .

Installation Procedure

Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable.




1. Install the brake rotor to the hub or the wheel.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the bolts that mount the brake rotor to the hub or the wheel using the J 44959 .

Tighten

•	Tighten the brake rotor bolts (9/16 in OD-10 bolt pattern) to 152 N·m (112 lb ft).

•	Tighten the brake rotor bolts (5/8 in OD-5 bolt pattern) to 256 N·m (189 lb ft).

Important: Ensure that the threads are clean and greaseless before applying the threadlock.

3. Apply 272 Threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of each brake rotor bolt.



4. Install the brake rotor (with the hub, or with the wheel). Refer to Front Wheel Hub, Bearing, and Seal Replacement .
5. Clean both sides of the brake rotor with denatured alcohol or an equivalent.
6. Install the brake caliper. Refer to Front Brake Caliper Replacement .
7. Install the wheel speed sensor ring using the J 45107 .
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

Important: Check the level of the brake fluid in the master cylinder reservoir after pumping the brake pedal.

10. Pump the brake pedal several times in order to ensure the pedal is firm and the brake pads are adjusted.
11. Remove the wheel blocks.

Front Brake Rotor Replacement 6500, 7500, 8500, FM6/FS7

Tools Required

Removal Procedure

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

1. Block the wheels.
2. Apply the parking brake.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .

Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

5. Remove the brake caliper. Refer to Front Brake Caliper Replacement .
6. Do not remove the brake line from the caliper.



7. Remove the brake rotor with the hub or with the wheel. Refer to Front Wheel Hub, Bearing, and Seal Replacement .



8. Remove the wheel speed sensor ring using the J 45107 .



9. Remove the bolts that mount the front brake rotor to the hub or the wheel using the J 44959 .
10. Remove the brake rotor from the hub, or the wheel .

Installation Procedure

Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable.




1. Install the brake rotor to the hub or the wheel.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolts that mount the brake rotor to the hub or the wheel using the J 44959 .

Tighten

•	Tighten the brake rotor bolts (9/16 in OD-10 bolt pattern) to 152 N·m (112 lb ft).

•	Tighten the brake rotor bolts (5/8 in OD-5 bolt pattern) to 256 N·m (189 lb ft).

Important: Ensure that the threads are clean and greaseless before applying the threadlock.

3. Apply 272 Threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of each brake rotor bolt.



4. Install the brake rotor (with the hub, or with the wheel). Refer to Front Wheel Hub, Bearing, and Seal Replacement .
5. Clean both sides of the brake rotor with denatured alcohol or an equivalent.
6. Install the brake caliper. Refer to Front Brake Caliper Replacement .
7. Install the wheel speed sensor ring using the J 45107 .
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

Important: Check the level of the brake fluid in the master cylinder reservoir after pumping the brake pedal.

10. Pump the brake pedal several times in order to ensure the pedal is firm and the brake pads are adjusted.
11. Remove the wheel blocks.

Front Brake Rotor Replacement 4500, 5500, FRX

Tools Required

Removal Procedure

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

1. Block the wheels.
2. Apply the parking brake.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .

Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

5. Remove the brake caliper. Refer to Front Brake Caliper Replacement .
6. Do not remove the brake line from the caliper.



7. Remove the brake rotor with the hub or with the wheel. Refer to Front Wheel Hub, Bearing, and Seal Replacement .



8. Remove the brake rotor from the vehicle.



9. Remove the wheel speed sensor ring using the J 45107 .



10. Remove the bolts that mount the front brake rotor to the hub or the wheel using the J 44959 .
11. Remove the brake rotor from the hub, or the wheel .

Installation Procedure

Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable.




1. Install the brake rotor to the hub or the wheel.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolts that mount the brake rotor to the hub or the wheel using the J 44959 .

Tighten

•	Tighten the brake rotor bolts (9/16 in OD-10 bolt pattern) to 152 N·m (112 lb ft).

•	Tighten the brake rotor bolts (5/8 in OD-5 bolt pattern) to 256 N·m (189 lb ft).

Important: Ensure that the threads are clean and greaseless before applying the threadlock.

3. Apply 272 Threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of each brake rotor bolt.



4. Install the brake rotor (with the hub, or with the wheel). Refer to Front Wheel Hub, Bearing, and Seal Replacement .
5. Clean both sides of the brake rotor with denatured alcohol or an equivalent.
6. Install the brake caliper. Refer to Front Brake Caliper Replacement .
7. Install the wheel speed sensor ring using the J 45107 .
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

Important: Check the level of the brake fluid in the master cylinder reservoir after pumping the brake pedal.

10. Pump the brake pedal several times in order to ensure the pedal is firm and the brake pads are adjusted.
11. Remove the wheel blocks.

Front Brake Rotor Replacement 4500, 5500,Non FRX

Tools Required

Removal Procedure

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

1. Block the wheels.
2. Apply the parking brake.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .

Notice: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

5. Remove the brake caliper. Refer to Front Brake Caliper Replacement .
6. Do not remove the brake line from the caliper.



7. Remove the brake rotor with the hub or with the wheel. Refer to Front Wheel Hub, Bearing, and Seal Replacement .



8. Remove the brake rotor from the axle.




Important: On some applications the wheel speed sensor ring is cast into the hub and is not removable. If the wheel speed sensor ring is damaged the hub assembly will need to be replaced.

9. If applicable, remove the wheel speed sensor ring using the J 45107 .



10. Remove the bolts that mount the front brake rotor to the hub or the wheel using the J 44959 .
11. Remove the brake rotor from the hub, or the wheel .

Installation Procedure

Notice: Any new rotor must have the protective coating removed from the friction surfaces before being placed in service. Remove the protective coating using denatured alcohol or an equivalent brake cleaner, and wipe the surface clean with clean cloths. Do not use gasoline, kerosene, or other oil base solvents which may leave an oily residue. This residue is damaging to the brake lining and is flammable.




1. Install the brake rotor to the hub or the wheel.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the bolts that mount the brake rotor to the hub or the wheel using the J 44959 .

Tighten

•	Tighten the brake rotor bolts (M12 x 15 or 9/16 in OD-10 bolt pattern) to 152 N·m (112 lb ft).

•	Tighten the brake rotor bolts (5/8 in OD-5 bolt pattern) to 256 N·m (189 lb ft).

Important: Ensure that the threads are clean and greaseless before applying the threadlock.

3. Apply 272 Threadlock GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of each brake rotor bolt.



4. Install the brake rotor (with the hub, or with the wheel). Refer to Front Wheel Hub, Bearing, and Seal Replacement .
5. Clean both sides of the brake rotor with denatured alcohol or an equivalent.
6. Install the brake caliper. Refer to Front Brake Caliper Replacement .
7. If applicable, install the wheel speed sensor ring using the J 45107 , if removed.
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .

Important: Check the level of the brake fluid in the master cylinder reservoir after pumping the brake pedal.

10. Pump the brake pedal several times in order to ensure the pedal is firm and the brake pads are adjusted.
11. Remove the wheel blocks.