1998 Chevrolet K1500 Pickup Brake Service (ONLINE REPAIR MANUALS)

Astro & Safari

• Apply parking brake.
• Disconnect reservoir and power steering hoses from booster.
• Remove master cylinder to brake booster retaining nuts.
• Position and support master cylinder away from booster. Do not remove hydraulic lines from master cylinder.
• Remove booster rod from top of brake pedal.
• Remove booster mounting nuts from inside of vehicle.
• Remove booster assembly and gasket.
• Reverse procedure to install, noting the following:
• Torque booster mounting nuts to 27 ft. lbs.
• Torque master cylinder retaining nuts to 27 ft. lbs.
• Torque power steering hoses to booster n...

Battery Ground Cable

Prior to service disconnect battery ground cable and isolate as required.

Radio Security System

Theftlock

If the Theftlock system is active when battery power is interrupted, the customers security code must be entered to restore proper function of the radio. To unlock a secured radio after power loss, proceed as follows:

• "LOC" appears with ignition in On position.
• Press "NM" and "000" will appear on display.
• Press "NM" again to make last two digits agree with security code.
• Press "HR" to make first 1 or 2 digits agree with security code.
• Press "AM-FM" to select code entered. "SEC" wi...

Certain general service procedures apply, regardless of whether the brakes are vacuum or hydraulically assisted. Only top quality, clean brake fluid should be used. More seals and valves are used with power brake systems than with ordinary brakes, so an inferior brake fluid will do much more damage. For the same reason, ensure all dirt is kept out of the system. Additionally, care must be taken not to mix the fluids of the booster hydraulic system and brake hydraulic system as the fluids are not compatible.

If the power unit fails, the brakes will still operate, as the convention...

C & K Series

Duo-Servo

Removal

• Raise and support vehicle.
• Mark relationship of wheel to hub, then remove tire and wheel assembly.
• On models equipped with full-floating axles, remove hub and drum assembly as described in "Drive Axles."
• On models equipped with semi-floating axles, proceed as follows:
• Install pin into park brake lever.
• Mark relationship of drum to axle.
• Remove rear brake drum retainers, as required.
• Remove rear brake drum.
• On all models, remove return springs and shoe guide, Fig. .
• Remove brake hold down springs and pins.
• Disconnect actuator lever and pivot.
• Remove lever return spri...

Removal

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

Installation

• Lubricate new sleeves, rubber bushings, bushing grooves and mounting bolt ends with lubricant part No. 19010909, or equivalent.
• Install new bushings and sleeves in caliper e...

Disassemble

• Place accumulator compressor tool No. J-26889, or equivalent, around end of accumulator.
• Install nut onto stud as shown in Fig. , then depress the accumulator with a C-clamp.
• Remove retainer by using a punch.
• Release C-clamp and remove accumulator compressor tool.
• Remove accumulator, O-ring, retainer, plug and spring, Fig. .
• Remove retainer, output pushrod, baffle, piston return spring and retainer.
• Using a suitable saw, cut off eyelet of pedal rod, then remove the boot.
• Remove nut, bracket and bolts, then separate cover from housing.
• Remove piston assembly and seal...