Service Procedure
1500 Series Vehicles^ J 46277 Rotor Removal Tool
^ J 6125-B Slide Hammer
1. Raise and suitably support the vehicle.
2. Remove the rear tire and wheel assemblies.
3. Remove the rear caliper bolts on one side.
4. Remove the caliper from the rotor (drum-in-hat) and support.
Note:
Use J 46277, Rotor Removal Tool, with J 6125-B, Slide Hammer, to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface.
5. Remove the rear rotor.
6. Remove the park brake shoe retaining clip (2).
7. Repeat Steps 3 through 6 for the other side.
8. Inspect the parking brake shoe lining (1) thickness in at least 6 places on each side of the vehicle. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install a new parking brake shoe on both sides.
9. Install a new park brake shoe retaining clip. If the parking brake shoe was replaced in the previous step, the new retaining clip was included in the kit.
Tighten
Tighten the bolt to 3 N.m (25 lb in).
10. Grind out the ridge in the drum section of the rotor, if necessary.
11. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (0.026 in).
12. Install the rotor.
13. Install the caliper to the rotor.
14. Perform the following procedure before installing the caliper guide pin bolts.
14.1. Remove all traces of the original adhesive patch.
14.2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
14.3. Apply Threadlocker, GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
15. Install the caliper bolts.
Tighten
Tighten the caliper guide pin bolts to 42 N.m (31 lb ft).
16. Repeat Steps 9 through 13 for the other rear caliper.
17. Install the tire and wheel assemblies.
Note:
A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surface, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in a wheel, nut, and/or stud damage.
Important:
Tighten the nuts evenly and alternately in order to avoid excessive run out.
18. Install the wheel nuts.
Tighten
Tighten the wheel nuts as shown to 190 N.m (140 lb ft).
19. Lower the vehicle.
2500/3500 Series Vehicles
^ J 46277 Rotor Removal Tool
^ J 6125-B Slide Hammer
^ J 2222-C Wheel Bearing Nut Wrench, or equivalent
^ J 8092 Universal Driver Handle - 3/4 inch - 10
^ J 44420 Differential Bearing and Hub Seal Installer
1. Hold the park brake activation pedal in the FULL upward position.
2. Pull rearward on the front park brake cable until the pedal drum (2) reaches its full reset position.
3. Insert a scribe or the shaft of a thin screwdriver (1) on an upward angle through the hole in the front of the pedal assembly, past the retracted pedal drum, and into the hole in the back of the pedal assembly (3).
4. Slowly release the cable.
5. Raise and suitably support the vehicle.
6. Remove the rear tire and wheels assemblies.
7. Remove the rear caliper bolts on one side.
8. Remove the caliper from the rotor (drum-in-hat) and support. Do not leave the caliper hanging from the hydraulic lines.
Note:
Use J 46277 Rotor Removal Tool with J 6125-B Slide Hammer to remove the rotor from the vehicle. Place J 46277 between the rotor surfaces in the vent section of the rotor. DO NOT place J 46277 on the back side of the rotor surface; it may damage the rotor surface.
9. For non dual rear wheels: Remove the rear rotor.
For dual rear wheels: Perform Steps 12 through 16 before Step 10.
10. Repeat Steps 7 through 9 for the other side of the vehicle.
11. Inspect the parking brake shoe lining thickness in at least 6 places on each side of the vehicle.
11.1. If the lining thickness is less than 1.5 mm (0.06 in) at any spot, install new parking brake shoes on both sides of the vehicle.
^ Non dual rear wheels: Continue to Step 12.
^ Dual rear wheels: Continue to Step 17.
11.2. If the lining thickness is more that 1.5 mm (0.06 in) in all spots, new parking brake shoes are not necessary.
^ Non dual rear wheels: Perform Steps 25 and 26, and then go to Step 38.
^ Dual rear wheels: Continue to Step 25.
12. Remove the axle shaft bolts and axle shaft.
12.1. Remove the flange bolts.
12.2. Lightly tap the axle shaft with a soft-faced hammer in order to loosen the shaft.
12.3. Grip the rib on the axle shaft flange with a pair of locking pliers. Twist the axle shaft flange in order to start the axle shaft removal
12.4. Remove the axle shaft from the tube.
12.5. Remove the gasket
12.6. Clean the axle shaft flange and the outside face of the hub assembly.
13. Remove the axle nut retaining ring.
14. Remove the key.
15. Remove the adjusting nut using the J 2222-C.
16. Remove the hub from the axle housing.
17. Remove the park brake shoe return spring (6).
18. Remove the park brake shoe anchor springs and pins (3).
19. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes (2) and adjuster assembly (5) from the vehicle.
20. Clean the debris and the dust from the park brake components using a clean shop cloth.
21. Install the adjuster assembly to the park brake shoes.
22. Separate the tips of the shoes and install the park brake shoes to the park brake actuator.
23. Install the park brake shoe anchor springs and pins.
24. Install the park brake shoe return spring (6).
25. Grind out the ridge in drum section of rotor if necessary.
26. Adjust the lining-to-drum clearance at the rear wheel to 0.6604 mm (.026 in).
27. Replace the hub seal using the J 44420, differential bearing and hub seal installer (2) and the J 8092, universal driver handle (1).
28. Install the hub to the axle housing.
29. Install and tighten the wheel bearing adjusting nut using the J 2222-C. Rotate the hub in the opposite direction to the way the adjuster nut is turning. Ensure that the inner bearing and the seal seats against the spindle shoulder.
Tighten
Tighten the adjusting nut to 70 N.m (52 lb ft).
30. Turn the adjusting nut counterclockwise until the nut is loose using the J 2222-C.
31. Turn the adjusting nut clockwise until the nut contacts the bearing cone. The torque on the nut must be zero to finger tight.
32. Insert the adjusting nut lock key into the keyway using one of the following procedures.
32.1. If the adjusting nut slot is in alignment with the keyway in the axle spindle, insert the adjusting nut lock key into the keyway in the axle spindle.
Important:
Do not turn the adjusting nut more than one slot counterclockwise in order to align the adjusting nut slot with the keyway in the axle spindle.
32.2. If the adjusting nut slot is not aligned with the keyway in the axle spindle, turn the adjusting nut counterclockwise until the adjusting nut slot is in alignment with the keyway in the axle spindle and insert the adjusting nut lock key.
33. Install the retaining ring.
34. Install the gasket and the axle shaft into the axle tube.
35. Ensure that the shaft splines mesh into the differential side gear.
36. Align the holes in the axle flange and the gasket with the holes in the hub.
Note:
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.
37. Install the axle flange bolts.
Tighten
^ For the 10.5 inch axle, tighten the rear axle flange bolts to 156 N.m (115 lb ft).
^ For the 11.5 inch axle, tighten the rear axle flange bolts to 200 N.m (148 lb ft).
38. Install the rotor.
39. Perform the following procedure before installing the brake caliper mounting bracket bolts:
39.1 Remove all traces of the original adhesive patch.
39.2 Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
39.3 Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
40. Install the brake caliper assembly and bolts.
Tighten the brake caliper mounting bracket bolts to
^ RPO JC5/JH5 to 200 N.m (148 lb ft)
^ RPO JH6 to 165 N.m (122 lb ft)
^ RPO JH7 to 300 N.m (221 lb ft)
41. Repeat this procedure for other side starting with Step 11.
42. Disconnect the cable for the right rear from the equalizer.
43. Remove the bolt from the rear axle clip.
44. Remove the cable from the differential clip.
45. Perform the following procedure to remove the cable (2) from the backing plate (4):
45.1 Compress the spring (3) by pushing towards the lever (1).
45.2 Depress the locking tabs.
45.3 Pull the cable housing out of the backing plate (4).
45.4 Remove the cable (2) through the slot in the backing plate.
46. Remove the park brake cable (2) from the lever (1).
47. Remove the cable from the vehicle.
48. Install the new cable to the vehicle.
49. Install the park brake cable (2) to the lever (1).
50. Perform the following procedure to install the cable (2) to the backing plate (4):
50.1 Compress the spring (3) by pushing towards the lever (1).
50.2 Route the cable (2) through the slot in the backing plate.
50.3 Push the cable housing into the backing plate (4) until the locking tabs snap into place.
51. Bolt the cable to the differential clips.
Tighten
Tighten the bolt to 25 N.m (18 lb ft).
Important:
After installing the cable to the rear axle holding clip, verify that the clip is securely retaining the cable. If not, crimp the clip by hand, taking care not to pinch or kink the cable.
52. Install the cable to the differential clip.
53. Connect the cable at the equalizer.
54. Install the wheels and tires.
55. Hold the park brake pedal in the FULL upward position.
56. Pull rearward on the front park brake cable until the tension is released from the scribe or nail (1) installed through the holes in the pedal assembly.
57. Remove the scribe or screwdriver (1).
58. Slowly release the park brake cable until it returns to its original position.
59. Release the park brake pedal.
Note:
A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel studs, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage.
60. Install the tire and wheel.
61. Install the wheel nuts.
Tighten
Tighten the wheel nuts as shown to 190 N.m (140 lb ft).
62. Install the wheel center cap.
63. Lower the vehicle.
64. Apply and release the park brake pedal to ensure that there is no binding or sticking.