1996 GMC C2500 Suburban Brake Service (ONLINE REPAIR MANUALS)

The Bendix single piston sliding caliper disc brake is standard equipment on some truck applications, while on other trucks it is used only in Hydro-Boost power brake applications with both front disc brakes and 4 wheel disc brakes. On 4 wheel disc brakes, the front and rear systems are identical.

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4WD Models

• Raise and support vehicle.
• Remove tire and wheel.
• Remove caliper as outlined under "Caliper Service."
• On ^K1500 and ^K2500 models, remove rotor.
• On K3500 models proceed as follows:
• Remove hub retaining nut.
• Remove four hub/rotor retaining bolts on back side of spindle.
• Using suitable wheel puller, remove rotor assembly.
• On K1500 and K2500 models, reverse procedure to install, tightening all bolts to specifications. Install caliper as outlined under "Caliper Service."
• On K3500 models, reverse procedure to install, noting the following:
• Torque hub nut to 173 ft. lbs
• Torque hub and bear...

Single Diaphragm Type

Disassemble

• Remove boot, silencer, vacuum check valve, grommet and front housing seal, Fig. .
• Scribe a line across front and rear housing, then mount brake booster to brake mounting fixture tool No. J 23456 or equivalent, Fig. .
• Turn fixture handle counterclockwise to unlock housings.
• Remove return spring, power piston assembly and power piston bearing from rear housing, Fig. .
• Remove reaction body retainer, piston rod, reaction retainer and filter.
• Remove power piston and pushrod assembly as follows:
• While holding the pushrod down against a hard surface, ...

Delco-Moraine Master Cylinder

Composite Type

When performing the following procedures, refer to Fig. for all models except Lumina APV, Silhouette & Trans Sport, noting that the composite reservoir may vary in design. Refer to Fig. for Lumina APV, Silhouette & Trans Sport models.

Disassemble

• Remove master cylinder from vehicle.
• Remove reservoir cover and diaphragm. Discard old brake fluid in reservoir.
• Inspect cover and diaphragm. Replace if cut, cracked or deformed.
• Remove fluid level switch and proportioning valve assembly, if equipped.
• Depress primary piston and remove lock ring.
• P...

Removal

• Remove caliper assembly as outlined above.
• Remove inboard pad with retainer spring. Dislodge outboard pad and position caliper on the front suspension so the brake hose will not support the weight of the caliper.
• Remove two sleeves from inboard ears of the caliper.
• Remove four rubber bushings from the grooves in each of the caliper ears.

Installation

• Lubricate new sleeves, rubber bushings, bushing grooves and mounting bolt ends with Delco Silicone Lube or equivalent.
• Install new bushings and sleeves in caliper ears. Position the sleeve so that the end toward the pad is flush ...

• Inspect components for damage or unusual wear. Replace as necessary.
• Inspect backing plate attaching bolts, and ensure they are tight.
• Inspect wheel cylinders. Excessive fluid indicates cup leakage and need for wheel cylinder replacement. A slight amount of fluid is always present and is considered normal, act...