Express 2500 V8-6.6L DSL Turbo (2010)
Brake Rotor/Disc: Removal and Replacement
Front Brake Rotor Replacement (JH5)
Front Brake Rotor Replacement (JH5)
Special Tools
*
J-41013 - Rotor Resurfacing Kit
*
J-42450-A - Wheel Hub Resurfacing Kit
Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning).
Removal Procedure
1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the
reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the
midway point before proceeding.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair).
5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair
).
6. If installing the original brake rotor, mark the relationship of the brake rotor to the hub.
7. Compress the brake caliper pistons.
1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard brake pad.
2. Slowly tighten the C-clamps until the caliper pistons are pushed completely into the caliper bores.
3. Remove the C-clamps from the caliper.
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible
brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which
may cause damage to the brake hose and in turn may cause a brake fluid leak.
Note: Remove the brake caliper bracket and the brake caliper as an assembly.
8. Remove the 2 brake caliper bracket mounting bolts.
9. Remove the caliper and bracket assembly and support with heavy mechanics wire or equivalent.
