Diesel Data: Automotive Repair
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Rear Brake Rotor Replacement (2500 Series)




Rear Brake Rotor Replacement (2500 Series)

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

6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation Removal and Replacement.

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





8. Compress the brake caliper pistons:

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

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

3. 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.

9. Remove the brake caliper bracket bolts.

10. Remove the caliper and caliper bracket as an assembly and support with heavy mechanics wire or equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.





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

12. 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.

13. Remove the rotor by slowly turning the rotor while pulling the rotor away from the axle.

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.





5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle.





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

7. Perform the following procedure before installing the brake caliper bracket bolts:

1. Remove all traces of the original adhesive patch.

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

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

Caution:
Refer to Fastener Caution Fastener Caution.

8. Install the brake 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 Removal and Replacement.

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 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads.

13. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. 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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