2000 Chevrolet C2500 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...

Removal

Front

• Siphon brake fluid out of master cylinder until fluid level is approximately ^1/3 full, this will prevent fluid overflow when caliper piston is pushed back into its bore.
• Raise and support vehicle, then remove wheels.
• Push piston back into its bore using suitable C-clamp, Fig. .
• Remove two caliper mounting bolts and lift caliper off of rotor.

Rear

Blazer, Bravada & Jimmy

• Raise and support vehicle.
• Mark position of wheel to hub for installation reference.
• Remove wheel assembly.
• Remove mounting bolt and disconnect brake hose fitting from caliper. Discard gaskets and plug brake h...

Delco Master Cylinder

When performing the following procedures, refer to Figs. and noting that the composite reservoir may vary in design.

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.
• Plug primary fluid outlet (outlet nearest to cowl when master cylinder is installed), then apply compressed air into secondary fluid outlet t...

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...

G Series

• Remove brake pipes from master cylinder. Plug pipes to prevent fluid contamination.
• Remove master cylinder attaching nuts and position master cylinder aside.
• Disconnect stop lamp switch electrical connector.
• Remove stop lamp switch retainer from brake pedal pin, then the stop lamp switch from brake pedal support.
• Disconnect power brake unit pushrod from brake pedal.
• Remove attaching nuts, then the power brake unit.
• Reverse procedure to install.
• Torque booster retaining nuts to 27 ft. lbs.
• Torque master cylinder retaining nuts to 27 ft. lbs.
• Torque brake pipe fittings...

Manual Bleed

• If vehicle is equipped with power brakes, remove vacuum reserve by applying brakes several times with engine off.
• Fill master cylinder reservoirs with suitable brake fluid. Ensure to always keep master cylinder reservoirs at least half full during entire bleeding procedure.
• If master cylinder is suspected to have air in the bore, it must be bled first. To bleed master cylinder, proceed as follows:
• Disconnect forward brake pipe connection at master cylinder.
• Allow brake fluid to fill master cylinder bore until it begins to flow from forward pipe connector port.
• Connect ...