How to Remove the Calipers from a 2002 Chevy Suburban

The Suburban is far-and-away the longest-running SUV in the GMC and Chevrolet lineups. It arrived back in 1936 as a modified panel truck. The next closest to the Suburban's age is the full-size Blazer, which lasted 25 years before Chevy changed its name to Tahoe. The 2002 Suburban came in two versions: 1500 and 2500. Changing the brake calipers is the same straightforward process on both trucks. After replacing the calipers, you must bleed the brake system.

Instructions

Removal

1

Unscrew the cap from the master cylinder reservoir and siphon out about half of the brake fluid with a clean turkey baster. Transfer this fluid to a small container.

2

Loosen the front or rear lug nuts, depending on if you are replacing the front or rear calipers, with a ratchet and socket. Raise the front or rear of the SUV, depending on what calipers you are replacing, with a floor jack and slide jack stands under the vehicles frame rails. Lower the Suburban onto the jack stands. Remove the lug nuts and pull the wheels off the Suburban.

3

Position an 8-inch C-clamp over the brake caliper, so the fixed part touches the rear of the caliper and the screw part touches the outer brake pad. Tighten the C-clamp until it stops moving, this compresses the internal caliper piston. Loosen the C-clamp and pull it off the caliper.

4

Wrap a clean, lint-free cloth around the center of the rubber brake hose to insulate it. Seal off the hose by closing a set of locking pliers over the clean, lint-free cloth. This prevents excess fluid loss and air introduction.

5

Slide a drain pan under the caliper. Remove the caliper hose banjo bolt with a ratchet and socket. Pull the brake hose from the caliper and discard the two brass washers.

6

Remove the two caliper guide pin bolts with a ratchet and socket, and pull the caliper off its bracket.

7

Repeat Steps 3 through 6 to remove the caliper on the other side of the Suburban.

Installation

8

Clean the old grease off the caliper guide pin bolts with a clean, lint-free cloth, if reinstalling the old caliper. Apply a generous coat of disc brake grease to the smooth parts of the guide pins do not get grease on the threaded part of the pins. On a new caliper, apply grease to the new caliper guide pin bolts that came with the caliper.

9

Set the caliper on the caliper bracket. Slide the caliper pins into the caliper and the caliper bracket, and hand-tighten the caliper guide pin bolts. Tighten the front caliper guide pin bolts to 80 foot-pounds with a torque wrench and socket. On the rear caliper, tighten the caliper guide pins to 31 foot-pounds on Suburban 1500 or 80 foot-pounds on a Suburban 2500.

10

Set a new brass washer included with the caliper onto the brake hose banjo bolt. Insert the banjo bolt through the brake hoses bolt hole and set the other brass washer on the banjo bolt. Remove the plastic cap on the new calipers inlet hole and hand-tighten the banjo bolt into the inlet hole.

11

Tighten the banjo bolt to 30 foot-pounds with a torque wrench and socket. Disengage the locking pliers from the brake hose.

12

Repeat Steps 1 through 4 to install the caliper on the other side of the Suburban.

Bleeding the Brakes

13

Fill the brake master cylinder to its Max line with fresh DOT 3 brake fluid. Keep the master cylinder reservoir from running out of fluid throughout the bleeding process.

14

Raise the side of the pickup not raised in the section titled Removal with a floor jack, and position jack stands under the frame rails. Lower the Suburban onto the jack stands.

15

Find the bleeder valve the -inch metal nipple on the rear of the right-rear brake caliper. Press a -inch-diameter rubber hose onto the end of the bleeder valve. Set the other end of the hose in a clean, clear container. Pour DOT 3 brake fluid into the container until fluid submerges the end of the hose.

16

Instruct an assistant to press and release the brake pedal repeatedly until it feels firm, then to hold pressure on the pedal. Open the bleeder valve by turning it about a half-turn counterclockwise with a combination wrench. Look at the end of the hose in the brake fluid and watch for bubbles to come from the hose. Tighten the bleeder valve to close it. Tell your assistant to release the brake pedal. Repeat this step until no bubbles come from the hose.

17

Refill the brake master cylinder to its Full line with fresh DOT 3 brake fluid.

18

Repeat Steps 3 through 5 on the remaining three calipers, in the following order: left rear, right front and left rear. Top off the master cylinder between each caliper. Do not let the master cylinder run dry, or you will have to start over.

19

Reinstall the wheels on the Suburbans hubs and hand-tighten the lug nuts. Lower the vehicle to the ground.

20

Tighten the lug nuts, in a crisscross pattern, to 140 foot-pounds with a torque wrench and socket.

21

Pump the brake pedal until it feels firm before driving the vehicle.

22

Take the old brake fluid to a used-automotive-fluid-recycling center for disposal. Some auto parts stores perform this task for free.