2003 Chevrolet Silverado 2500 HD Brake Service (ONLINE REPAIR MANUALS)

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...

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...

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...

Aztek & Rendezvous

• Remove coolant reservoir, then relieve fuel system pressure as outlined under. "Precautions."
• Remove cruise control cable from module, then disconnect electrical connector from cruise control module.
• Remove cruise control module from bracket, then the front end sheet metal diagonal brace.
• Remove PCM cover from air cleaner housing, then the PCM and set aside.
• Remove air cleaner intake duct, then bolts from air cleaner assembly and housing.
• Remove fuel lines from pipes and vapor line, then disconnect fluid level sensor switch from brake master cylinder.
• Disc...

Accessing Diagnostic Trouble Codes

Connect a suitably programmed scan tool to Data Link Connector (DLC) and follow manufacturers instructions.

Diagnostic Trouble Code Interpretation

Astro, Blazer, Jimmy, Safari, Sonoma, SSR & S10

Avalanche, Escalade, Escalade EXT, Suburban, Tahoe & Yukon

2002

2003-06

Bravada, Envoy, Rainier & Trailblazer

2002-03

2004-06

Express & Savana

2002

2003-06

Sierra & Silverado

2002

2003-06

Connector Pin Identification

Diagnostic Tests

Astro, Blazer, Jimmy, Safari, Sonoma, SSR & S10

Avalanche, Escalade, Escalade EXT, Suburban, Tahoe & Yukon

2002

2003-06

Bravada, Envoy, Rai...

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, the amount of asbestos dust from brake lining wear is at a low level because of a chemical breakdown during use and a few precautions will minimize exposure.. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessiv...