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Home >> Chevy Truck >> 2013 >> Express 3500 V8-6.0L >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Rotor/Disc >> Service and Repair >> Removal and Replacement >> Rear Brake Rotor Replacement (JH5, JH6)

Rear Brake Rotor Replacement (JH5, JH6)




Rear Brake Rotor Replacement (JH5, JH6)

Special Tools

* J-2619-01 - Slide Hammer with Adapter

* J-41013 - Rotor Resurfacing Kit

* J-42450-A - Wheel Hub Resurfacing Kit

* J46277 - Rotor Removal Tool

Warning:
Refer to Brake Dust Warning Brake Dust Warning.


Removal Procedure





1. Release the park brake.

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

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

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.

8. Remove the brake caliper bracket bolts.

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.

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

10. Remove the 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 brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it while pulling outward.





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

1. Assemble the J46277 - Rotor Removal Tool to the J-2619-01 - Slide Hammer with Adapter.

2. Insert the J46277 - Rotor Removal Tool between the rotor friction surfaces in the vent section of the rotor. DO NOT place the J46277 - Rotor Removal Tool on the rotor friction surface.

3. Using the J46277 - Rotor Removal Tool and the J-2619-01 - Slide Hammer with Adapter, remove the rotor from the hub assembly.

4. Inspect the park brake components for the following conditions:

* Bent or broken springs

* Broken, cracked or worn brake shoe lining

* Bent or damaged brake shoe

* Worn, bent or damaged backing plate

5. Replace any damaged components.

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 Kit to clean all rust and contaminants from the mating surface of the hub flange.

2. Use the J-41013 - Rotor Resurfacing Kit 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. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle.





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

7. Prepare the brake caliper bracket bolts for installation:

1. Remove all traces of the original adhesive patch.

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

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

4. Allow the threadlocker to cure approximately 10 minutes before installation.

Caution:
Refer to Fastener Caution Fastener Caution.

8. Install the caliper bracket bolts and tighten to 200 Nm (148 lb ft).

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.

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