Express 2500 2WD V8-4.8L VIN V (2004)
4. Mark the relationship of the rotor to the hub.
5. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad.
6. Slowly tighten the C-clamp until the pistons are pushed into the caliper bores enough to remove the caliper from the pads.
7. Remove the C-clamp from the caliper.
8. Notice:
Support the brake caliper with heavy mechanic's 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.
Remove the brake caliper and brake caliper bracket as an assembly and support with heavy mechanic's wire or equivalent. DO NOT disconnect the
hydraulic brake flexible hose from the caliper.
9. Remove the rotor retaining push nuts from the wheel studs, if applicable.
10. It may be necessary to strike the end of the hub or the rotor with a deadblow hammer to separate the rotor from the hub.
11. Remove the rotor.
12. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor, 25 and 35 series only.
1. Clean all the surface areas and the threaded holes of contamination.
2. Generously apply penetrating oil or the equivalent to the hub/rotor area.
3. Insert two M10 x 1.5 bolts or jack screws into the threaded holes of the rotor.
4. Tighten both bolts evenly to force the rotor from the hub.
Installation Procedure
1. Important:
Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and
