Document ID# 777700
(2003) Chevrolet Avalanche
(2003) Chevrolet Avalanche
Brake Caliper Replacement - Front
Removal Procedure
Caution: Use Brake Dust Caution!
Caution: Use Brake Fluid Irritant Caution!
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Compress the brake caliper pistons.
? Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.
? Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.
? Remove the C-clamp from the caliper.
7. Clean all dirt and foreign material from the brake hose end.
Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.
8. Remove the brake hose to caliper bolt from the brake caliper.
9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
10. Remove the brake hose from the caliper.
11. Remove the 2 brake caliper mounting bolts.
Caution: Do not depress the brake pedal with the brake rotors/calipers and/or the brake drums removed. Damage to the brake system may result. If brake system damage occurs and is not repaired, vehicle damage and/or personal injury or death may result.
12. Remove the brake caliper from the brake caliper mounting bracket.
Installation Procedure
1. Install the brake caliper to the brake caliper mounting bracket.
2. Perform the following procedure before installing the caliper mounting bolts.
1. Remove all traces of the original adhesive patch.
2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 1095348
to the threads of the bolt.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.
3. Install the 2 brake caliper mounting bolts.
Tighten
Tighten the bolts to 108 N?m (80 lb ft).
4. Remove the rubber cap or plug from the exposed brake hose fitting end.
Important: Install 2 new copper brake hose gaskets.
5. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.
6. Install the brake hose to caliper bolt to the brake caliper.
Tighten
Tighten the brake hose to caliper bolt to 40 N?m (30 lb ft).
7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
9. Lower the vehicle.
10. Fill the master cylinder reservoir to the proper level with clean brake fluid.