Question about 2002 Chevrolet Silverado

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2002 silverado 2500HD rear brake question????

2 wheel drive 6.0 litre rear disk. How do I get the caliper bolt out?The leaf spring is right in front of it with less than 2 inches between them.Do you know which star bit I need for this?55 or 60mm.thanks

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You'll need a T-55 torx bit to remove the rear caliper pins/bolts. You can try using an insert style bit...one that removes from the socket or perhaps purchase a replacement bit (one that would be used in a cordless drill/driver.) The one I used had a 5/16" hex shank. Like you said, there is very little clearance between the head and the leaf springs, which won't allow room for a breaker bar and torx bit. So using a 5/16" wrench, ( I'd recommend a 6 point box wrench to prevent slipping or rounding off.) I was able to loosen the bolt. Or plan B is to remove the caliper mounting bracket which is held on by two 21 or 22 mm hex head bolts. Which would have to be removed to remove the brake rotor.

Posted on Jun 03, 2009

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Tools:
1. Combination Wrench Set
2. 3/8 in. Drive Ratchet
3. Floor Jack
4. Jack Stand Set
5. C-Clamp
6. Mallet Hammer
7. Flat Head Screwdriver
8. Socket Set
9. Tire Iron
10. 1/4 in. Drive Torque Wrench

Supplies:
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Steps:
Step 1 Park your vehicle on a solid level surface. Set the parking brake and chock the rear wheels.
o Tip: Safety Tip:Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or safety shoes.

Step 2 Remove the front wheel hub caps if applicable. Using a tire iron, break loose the front wheel lug nuts but do not remove.
o Tip: Lug nuts fasten the wheel to the hub and may be on very tight. To gain more leverage, use a breaker bar to loosen the nuts.

Step 3 Using a floor jack, lift up the front of your vehicle.
o Tip: Using an aftermarket floor jack, instead of the original equipment (OE) jack, can make the job easier and safer. Verify the condition of the floor jack before use.

Step 4 Secure the vehicle with jack stands on both sides for safety before starting any work. The pinch welds or the frame rails are the two best locations. Do not rely on the jack to hold the vehicle up while working.
o Tip: Try to find a flat, level, and strong surface to put the jack stands.

Step 5 Remove the front wheel lug nuts. Remove the front wheels and set them aside.

Step 6 Inspect the brake caliper for any signs of binding. Look for rust and uneven brake pad wear.

Step 7 Remove the brake caliper mounting bolts (sliding bolts).

Step 8 Support the caliper up and away from the working area. Make sure you do not kink or pinch any brake lines.
o Tip: Use a bungee cord to secure the brake caliper out of the way and hang it on the suspension spring.

Step 9 Clean the sliding bolts and lubricate them.

Step 10 Install the new caliper over the brake pads and rotor. Attach the caliper to the mounting bracket with the sliding bolts. Tighten the caliper sliding bolts to manufacturer’s specifications.

Step 11 Disconnect the brake line from the old caliper. Attach the brake line to the new caliper using new copper washers. Tighten the banjo bolt.

Step 12 Repeat for the other side. Bleed the front brakes.

Step 13 Reinstall the front wheels. Torque the lug nuts to the manufacturer specifications in a star pattern.

Step 14 Remove jack stands and lower the vehicle to the ground.

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Hope this help (remember rated this).

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1 Answer

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How to Replace a Brake Caliper
(DIY Complexity: Moderate / Time: 2.1 hours)

Parts:
1. Brake Caliper

Tools:
1. Combination Wrench Set
2. 3/8 in. Drive Ratchet
3. Floor Jack
4. Jack Stand Set
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6. Mallet Hammer
7. Flat Head Screwdriver
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9. Tire Iron
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Supplies:
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Steps:
Step 1 Park your vehicle on a solid level surface. Set the parking brake and chock the rear wheels.
o Tip: Safety Tip:Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or safety shoes.

Step 2 Remove the front wheel hub caps if applicable. Using a tire iron, break loose the front wheel lug nuts but do not remove.
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Step 3 Using a floor jack, lift up the front of your vehicle.
o Tip: Using an aftermarket floor jack, instead of the original equipment (OE) jack, can make the job easier and safer. Verify the condition of the floor jack before use.

Step 4 Secure the vehicle with jack stands on both sides for safety before starting any work. The pinch welds or the frame rails are the two best locations. Do not rely on the jack to hold the vehicle up while working.
o Tip: Try to find a flat, level, and strong surface to put the jack stands.

Step 5 Remove the front wheel lug nuts. Remove the front wheels and set them aside.

Step 6 Inspect the brake caliper for any signs of binding. Look for rust and uneven brake pad wear.

Step 7 Remove the brake caliper mounting bolts (sliding bolts).

Step 8 Support the caliper up and away from the working area. Make sure you do not kink or pinch any brake lines.
o Tip: Use a bungee cord to secure the brake caliper out of the way and hang it on the suspension spring.

Step 9 Clean the sliding bolts and lubricate them.

Step 10 Install the new caliper over the brake pads and rotor. Attach the caliper to the mounting bracket with the sliding bolts. Tighten the caliper sliding bolts to manufacturer’s specifications.

Step 11 Disconnect the brake line from the old caliper. Attach the brake line to the new caliper using new copper washers. Tighten the banjo bolt.

Step 12 Repeat for the other side. Bleed the front brakes.

Step 13 Reinstall the front wheels. Torque the lug nuts to the manufacturer specifications in a star pattern.

Step 14 Remove jack stands and lower the vehicle to the ground.

Step 15 Verify that you have a solid brake pedal. Road test the vehicle to verify brake caliper repair.


Hope this help.

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2 Answers

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