FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Chevy Truck >> 2012 >> Express 3500 V8-6.0L >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Rotor/Disc >> Service and Repair >> Removal and Replacement >> Front Brake Rotor Replacement (JH6, JH9)

Front Brake Rotor Replacement (JH6, JH9)




Front Brake Rotor Replacement (JH6, JH9)

Special Tools

* J-41013 - Rotor Resurfacing Kit

* J-42450-A - Wheel Hub Resurfacing Kit

Warning:
Refer to Brake Dust Warning Brake Dust Warning.


Removal Procedure





1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Service and Repair.

3. Remove the front wheel hub extension, if equipped.

1. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning.

2. Mark the relationship of the front wheel hub extension to the hub.

3. Remove the front wheel hub extension bolts.

4. Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a non-metallic mallet to loosen it from the hub.





4. Mark the relationship of the rotor to the hub.

5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.

6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads.

7. Remove the C-clamp from the caliper.





Caution:
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.

8. Without disconnecting the hydraulic brake hose, remove the brake caliper bracket bolts and remove the brake caliper and bracket as an assembly and support with heavy mechanics wire or equivalent.

9. Remove the rotor retaining push nuts from the wheel studs, if applicable.

10. 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.





11. Remove the rotor.

12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only.

1. Clean all the surface areas and the threaded holes of contamination.

2. Generously apply penetrating oil or the equivalent to the hub/rotor area.

3. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor.

4. Tighten both bolts evenly to force the rotor from the hub.

Installation Procedure

Note:
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 - Wheel Hub Resurfacing Kitto clean all rust and contaminants from the mating surface of the hub flange.

2. Use the J-42450-A - Wheel Hub Resurfacing Kitto 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.





Note:
If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.

4. Align the rotor to its original position on the hub (if applicable) and install the rotor.





5. Install the caliper and caliper bracket assembly.

6. Prepare the brake caliper bracket bolts for installation:

* Remove all traces of the original adhesive patch.

* Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.

* Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to 2/3 of the threaded portion of the bolt.

* Allow the threadlocket to cure approximately 10 minutes before installaton.

Caution:
Refer to Fastener Caution Fastener Caution.

7. Install the caliper bracket bolts and tighten to 300 Nm (221 lb ft).





8. Install the front wheel hub extension, if equipped.

1. Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning.

2. Align and install the front wheel hub extension to the original position on the hub.

3. Following the wheel nut tightening sequence, install the front wheel hub extension nuts and tighten to 130 Nm (96 lb ft). Refer to Tire and Wheel Removal and Installation Service and Repair.

9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Service and Repair.

10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.

11. Slowly release the brake pedal.

12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained. This will properly seat the brake caliper pistons and brake pads.

13. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling.

14. If the brake rotor was refinished or replaced, burnish the brake pads and rotors. Refer to Brake Pad and Rotor Burnishing Procedures.

pro multis Credits:Operation CHARM About Operation CHARM