2000 Chevrolet K3500 Pickup Brake Service (ONLINE REPAIR MANUALS)

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...

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...

Master Cylinder

Some vehicles use a conventional tandem master cylinder with two hydraulic pistons operating in-line. The primary piston controls the front brake system and the secondary piston controls the rear brake system.

Other models use a master cylinder that operates the same as the conventional master cylinder, but also incorporates a quick take-up feature in the rear chamber to reduce excessive pedal travel which may result from increased fluid displacement required to move the low drag caliper piston out against the rotor.

The quick take-up uses a spring-loaded ball check val...

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...

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 ...

General System

• Inspect components for damage or unusual wear. Replace as required.
• Inspect backing plate mounting bolts and ensure they are tight.
• Inspect wheel cylinders. Excessive fluid indicates cup leakage and need for wheel cylinder replacement. Slight amount of fluid is always present and is considered normal, acting as lubricant for cylinder pistons.
• Check adjuster screw operation. If satisfactory, lightly lubricate adjusting screw and washer with suitable brake lube. If operation is unsatisfactory, replace.
• C clean rust and dirt from shoe contact surfaces on backing plate using fi...