1995 suburban 4x4 k2500 front brake rotor replacement?

Answer 1

I just replaced my front rotors on my 1996 Chevy K2500 4x4. This is how I did it:Removing: Loosen lug nuts (7/8") and spindle nut (36mm). Lift truck. Remove lug nuts, spindle nut, and wheel. Remove 2 bolts (3/8" Allen) holding calipers on. Hold the calipers up with a bungee cord. I attached it to the sheet metal of the fender. Remove 4 bolts (15mm) from rear of hubs. Once these bolts are removed you can move the shield that is in-between the hub and the axle(I think). You are moving it to get access to the Allen bolt that holds the ABS sensor on. Once you move the shield then you can look through the top of the rotor through the slots and see the sensor line and bolt. I don't remember what size Allen this one took. You do need a long Allen wrench though. Disconnect sensing line from hub. Now the rotor is ready to come off. I had to use a pry bar to remove this gently working each side until it popped off. Once the rotor is removed, you need to hammer out the lug bolts. Then you have to tap the rotor away from the hub. This took a little work. Then check each of the lug bolts by screwing the lug nuts on them. They should go all the way down by hand. If they don't - go buy new bolts $2 a piece. Installing: Position new rotor on hub. Get some dry ice from your local grocery store and freeze the bolts for about 10 minutes. Pull one bolt out of the ice at a time and install on the rotor and tighten the bolt with the lug nut. I put the nuts on upside down and used a 7/8" wrench and mallet to tap on the wrench to get these as tight as possible. You also have to tap on the head of the bolt and repeat the wrench tapping. Do this for each bolt pulling one out of the ice at a time. You do not have to get the rotor and hub completely together but get it as close together as possible. Once all of the lug bolts are in it is time to put the rotor on the truck. Ensure the shield is on the spindle and install the rotor, again, this takes some work. Once the rotor is on, connect the ABS sensing line. Line up the shield and install 4 bolts to rear of hub. You can align these by moving the hub, not the rotor. Install the caliper, remember to put brake grease on these 2 bolts. You may have to compress the caliper slightly. To do this remove the brake pad that has the circular part of the caliper touching it. Open the brake fill cap on the master cylinder. Use a C-clamp to compress the circular part. Reinstall the brake pad and brake fill cap. Install the caliper. Install the wheel and tighten lug nuts. I used a cheater bar on my tire iron and ensured that the lug bolts were flush with the head of the lug nuts. Then I removed the wheel to verify that the gap between the rotor and the hub was gone. Reinstall wheel, tighten lug nuts, and tighten spindle nut. Once both brakes have been replaced, start up the truck and pump the brakes several times till you feel some tension when pressing them.