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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2003 Chevrolet Express 3500 car and truck
repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
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BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2003 Chevrolet Express 3500 cars and light trucks from 1990+.
Power Brake Units -> Bendix Brake Booster -> Troubleshooting -> Accumulator Leak-Down, System Does Not Hold Charge -> Grabby Brakes Or Booster Chatters/Pedal Vibrates -> Slow Brake Pedal Return
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
Slow Brake Pedal Return
- Excessive seal friction in booster.
- Faulty spool action.
- Restriction in return line from booster to pump reservoir.
- Damaged input rod end.
Grabby Brakes Or Booster Chatters/Pedal Vibrates
- Faulty spool action caused by contamination in sys...
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BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2003 Chevrolet Express 3500 cars and light trucks from 1990+.
Hydraulic Brake Systems -> Description -> Hydraulic Control Valves -> Master Cylinder
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
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...
CLICK HERE TO GET FULL ACCESS TO 2003 Chevrolet Express 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2003 Chevrolet Express 3500 cars and light trucks from 1990+.
Power Brake Units -> Delco Brake Booster -> Power Brake Unit Service Replacement
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
The power brake uni...
CLICK HERE TO GET FULL ACCESS TO 2003 Chevrolet Express 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2003 Chevrolet Express 3500 cars and light trucks from 1990+.
Power Brake Units -> Bendix Brake Booster -> Power Brake Unit Service -> Accumulator Service -> Assemble -> Booster Bleed -> Cleaning & Inspection -> Disassemble
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
Disassemble
- Place accumulator compressor tool No. J-26889, or equivalent, around end of accumulator.
- Install nut onto stud as in. Fig. , then depress 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.
- Cut off eyelet of pedal rod, then remove boot.
- Remove nut, bracket and bolts, then separate cover from housing.
- Remove piston assembly and seals.
- Remove spool valve, then the accu...
CLICK HERE TO GET FULL ACCESS TO 2003 Chevrolet Express 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2003 Chevrolet Express 3500 cars and light trucks from 1990+.
Power Brake Units -> Bendix Brake Booster -> Power Brake Unit Replacement -> Astro & Safari -> C & K Series -> Express & Savana -> P Series
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
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...
CLICK HERE TO GET FULL ACCESS TO 2003 Chevrolet Express 3500 BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2003 Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2003 Chevrolet Express 3500 cars and light trucks from 1990+.
Power Brake Units -> Delco Brake Booster -> General Service
Vehicle: 2003 Chevrolet Express 3500 6.0 V8 GAS
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, on models with hydraulic assist brakes, 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 brak...
CLICK HERE TO GET FULL ACCESS TO 2003 Chevrolet Express 3500 BRAKE SERVICE PROCEDURES
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