- Remove the cover on the master cylinder and siphon enough fluid out of the reservoirs to bring the level to 2/3 full. This step prevents spilling fluid when the piston is pushed back.
- Raise and support the vehicle. Remove the front wheels and tires.
- Push the brake piston back into its bore using a C-clamp to pull the caliper outward.
- Unfasten the brake hose fitting from the caliper using a flare nut wrench, cap the fitting to prevent foreign material from entering the or the hose.
- Remove the two bolts which hold the caliper and then lift the caliper off the disc.
If the pads are to be reinstalled, mark them inside and outside.
- Remove the inboard and outboard shoe.
- Remove the pad support spring from the piston.
- Remove the two sleeves from the inside ears of the caliper and the 4 rubber bushings from the grooves in the caliper ears.
- Remove the caliper.
- Check the inside of the caliper for fluid leakage; if so, the caliper should be overhauled.
- Lubricate the sleeves, rubber bushings, bushing grooves, and the end of the mounting bolts using silicone lubricant.
- Install new bushing in the caliper ears along with new sleeves. The sleeve should be replaced so that the end toward the shoe is flush with the machined surface of the ear.
- Install the brake pads.
- With the two pads in position, place the caliper over the brake disc and align the holes in the caliper with those of the mounting bracket.
For best results, always use new bushings, sleeves and bolt boots.
- Fill the cavity between the bolt bushings with silicone grease. Install the mounting bracket bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure that the ends of the bolts pass under the retaining ears on the inboard pad.
After tightening the mounting bolts, there must be clearance between the caliper and knuckle at both the upper and lower edge. On R/V Series, the clearance must be 0.010-0.024 in. (0.26-0.60mm); on C/K Series, it must be 0.005-0.012 in. (0.13-0.30mm) for 1988-91, and 0.010-0.028 in. (0.26-0.71mm) on 1992-98 models. If not, loosen the bolts and reposition the caliper.
- Tighten the mounting bolts to 35 ft. lbs. (47 Nm) for R/V Series; 28 ft. lbs. (38 Nm) for 1988-92 C/K Series and 38 ft. lbs. (51 Nm) for 1993-98 C/K Series.
- Connect the brake hose to the caliper and tighten the fitting until the are snug.
- Pump the brake pedal to seat the pad against the rotor. Don't do this unless both calipers are in place. Use a pair of channel lock pliers to bend over the upper ears of the outer pad so it isn't loose.
- Install the front wheel and lower the truck.
- Add fluid to the master cylinder reservoirs so that they are 1/4 in. (6mm) from the top.
- Bleed the brake system.
- Check the fluid level again and add fluid as necessary. Do not move the vehicle until a hard pedal is obtained.