How to Change the Rotors on a 2500 Chevyby Dan Ferrell
If you have detected a worn or damaged brake rotor on your 2500 Chevy model, you need to change it as soon as possible. Although a relatively simple task, removal and installation requires proper handling of brake assembly components and a new rotor to prevent damage, ensure the good operation of the brake system and keep you safe on the road. With the required tools, and possible tools you may need handy, you can safely perform the job at home.
Removing the Rotor
Park your Chevy pickup in a safe and level place. Shift the transmission to neutral (N).
Using a clean rag, clean the cap and body of the brake master cylinder reservoir.
Draw at least two-thirds of the brake fluid from the master cylinder using a clean turkey baster and an appropriate container. Set the cap back in place but loose.
With a lug wrench, loosen the wheel lug nuts on the wheel/tire assembly with the rotor you are changing.
Raise the wheel/tire assembly using a floor jack and support it on a jack stand. Finish removing the wheel/tire.
Retract the brake caliper pistons into their bore using a large C-clamp. Position the clamp over the caliper and use the clamp screw to push against the brake pad to force the pistons back.
Remove the two brake caliper bracket mounting bolts using a ratchet, ratchet extension and socket.
Lift the caliper and mounting bracket as an assembly off the rotor and secure it to the coil spring using a piece of heavy wire. Leaving the caliper and bracket hanging loose will damage the brake hose connected to the caliper.
Remove the rotor from the hub. If the rotor seems stuck, clean the hub and rotor assembly, including the threaded holes in the rotor, with brake parts cleaner and a clean, lint-free rag. Then, if you are changing a front rotor, install two M10-by-1.5 bolts into the threaded holes of the rotor. Tighten the bolts evenly and gradually with a ratchet and socket to pull the rotor free. On rear wheels, rotate as you pull the rotor off the hub. Alternatively, use a slide hammer with a hooked end and pull the rotor from the vents on the edge.
Installing the New Rotor
Clean the hub flange-mating surface with brake parts cleaner, a soft brush and a clean, lint-free rag.
Wipe the friction surfaces of the new rotor with brake parts cleaner and a clean, lint-free rag to remove the protective film.
Position the new rotor in place.
Remove the caliper and bracket assembly from the coil spring and set it in place over the rotor.
Clean the caliper bracket mounting bolts with a wire brush, brake parts cleaner and a clean, lint-free rag.
Coat the threads of the caliper bracket mounting bolts with a threadlocker.
Install and start the caliper bracket bolts by hand. Then, tighten the bolts using the ratchet, ratchet extension and socket.
Install the tire and, with the lug wrench, tighten the wheel lug nuts.
Lower the vehicle and finish tightening the wheel lug nuts.
Slowly pump the brake pedal several times to help the caliper pistons and brake pads properly seat over the new rotor.
Fill the brake master cylinder with new brake fluid to bring the level up to the "Full" mark.
- Chevrolet Silverado GMC Sierra: 1999 thru 2006 2WD and 4WD (Haynes Repair Manual); Jeff Kibler and John H. Haynes; 2008
Things You'll Need
- Clean rag
- Clean turkey baster
- Lug wrench
- Floor jack
- Jack stand
- Large C-clamp
- Ratchet extension
- Heavy wire
- Brake parts cleaner
- Clean, lint-free rag
- 2 M10-by-1.5 bolts, if necessary
- Slide hammer, if necessary
- Soft brush
- Wire brush
- New brake fluid
Since 2003 Dan Ferrell has contributed general and consumer-oriented news to television and the Web. His work has appeared in Texas, New Mexico and Miami and on various websites. Ferrell is a certified automation and control technician from the Advanced Technology Center in El Paso, Texas.