Brake Caliper Rebuild - Rear

This procedure covers disassembly, rebuild, and reinstallation of the rear brake calipers on a 2014-2018 Chevrolet Silverado 1500 5.3L V8, including cleaning, seal replacement, and system bleeding.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (includes pistons, seals, boots) × 2 — Use OEM specification or quality aftermarket
• Brake fluid × 1 — ACDelco DOT 4
• Copper crush washers for brake line banjo bolts × 4 — If applicable to caliper design

Fluids

• ACDelco DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Loosen rear wheel lug nuts while vehicle is on ground
3. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
4. Remove rear wheels completely
5. Locate brake fluid reservoir under hood and remove cap to prevent vacuum formation during bleeding
6. Place drip pans under work area to catch brake fluid
7. Inspect brake lines and hoses for damage or corrosion before beginning work

Procedure

1. 1

   Remove rear brake caliper
   Use a line wrench to loosen the brake line fitting at the caliper. Once loose, use a catch pan as fluid will drain. Remove the caliper slide pin bolts using appropriate socket. Lift caliper off bracket and completely disconnect brake line. Cap or plug brake line immediately to prevent fluid loss and contamination.
   ⚠Brake fluid will drain from line. Have catch pan ready and cap line immediately to prevent air entry and fluid loss.
   Torque spec

   Line Fittings26 Nm (19 lb-ft)

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Inspect and clean caliper exterior
   Place caliper on clean workbench. Spray exterior with brake cleaner and wipe down with clean rags. Inspect caliper body for cracks, severe corrosion, or damage. If caliper body is cracked or severely pitted, replacement is required instead of rebuild. Remove rubber dust boots from pistons.
3. 3

   Remove caliper pistons
   Place caliper in bench vise with soft jaws or on padded surface. If using compressed air method: place a block of wood or thick rag inside caliper to catch piston, then apply compressed air to brake line port to push piston out. Control air pressure carefully. Alternatively, use brake caliper piston tool or C-clamp to carefully work piston out by hand. Repeat for second piston if dual-piston caliper. Do not allow pistons to come out with force.
   ⚠️Compressed air can eject piston with extreme force causing serious injury. Use minimal pressure and always have padding to catch piston. Keep hands clear of piston path.
4. 4

   Remove internal seals
   Using a plastic pick tool or seal remover, carefully pry out the piston seals from their grooves inside the caliper bores. Remove all old seal material completely. Inspect caliper bores for scoring, pitting, or corrosion. Light surface rust can be cleaned with crocus cloth, but deep scoring requires caliper replacement.
   ⚠Do not use metal tools that could scratch or gouge the caliper bore surfaces. Damaged bores will leak and cause brake failure.
5. 5

   Clean caliper bores and components
   Thoroughly clean all caliper internal passages, bores, and external surfaces with brake cleaner. Use wire brush on non-critical surfaces only. Dry completely with compressed air or clean lint-free rags. Inspect pistons from rebuild kit or cleaned original pistons for chrome damage, pitting, or scoring. Any damaged pistons must be replaced.
6. 6

   Install new piston seals
   Coat new piston seals lightly with clean DOT 4 brake fluid. Carefully install seals into their grooves in the caliper bores, ensuring they seat completely and evenly without twisting. Verify seals are properly positioned in grooves all the way around.
7. 7

   Install pistons and dust boots
   Coat new or cleaned pistons generously with clean DOT 4 brake fluid. Carefully insert pistons straight into caliper bores, being extremely careful not to damage seals. Push pistons in evenly using hand pressure or caliper tool until they bottom in their bores. Install new dust boots over pistons and seat properly in caliper body grooves.
   ⚠Pistons must go in straight and evenly. Cocked pistons will damage seals causing brake failure. Do not use excessive force.
8. 8

   Clean and lubricate slide pins
   Remove caliper slide pins from bracket if not already removed. Clean pins thoroughly with brake cleaner and inspect for corrosion or wear. Clean slide pin bores in bracket. Apply thin coat of high-temperature silicone brake grease to slide pins (not petroleum-based grease). Reinstall slide pins in bracket ensuring they move freely.
   ⚠Use only silicone brake grease on slide pins. Petroleum-based grease will destroy rubber components and cause caliper seizing.
9. 9

   Reinstall caliper to bracket
   If brake line has copper crush washers (banjo bolt style), install new washers on both sides of fitting. Position rebuilt caliper over brake rotor and bracket. Apply medium-strength thread locker to caliper slide pin bolts. Thread slide pin bolts by hand first to ensure proper threading, then torque to specification.
   ℹ️Thread locker prevents slide pin bolts from backing out due to vibration. Use only medium-strength thread locker.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Reconnect brake line
    Remove cap or plug from brake line. Using line wrench, connect brake line to caliper and torque fitting to specification. Do not overtighten as this can strip the fitting or crack the line. Ensure fitting is properly seated and not cross-threaded.
    Torque spec

    Line Fittings26 Nm (19 lb-ft)
11. 11

    Bleed rear brake caliper
    Attach clear tubing to bleeder screw and place other end in catch bottle with small amount of clean brake fluid. Have assistant pump brake pedal 3-4 times and hold pressure. Open bleeder screw and allow fluid and air to escape until stream is solid without bubbles, then close bleeder screw before pedal reaches floor. Repeat until no air bubbles appear. Top off brake fluid reservoir frequently during bleeding process. Torque bleeder screw to specification.
    ⚠️Never allow brake fluid reservoir to run empty during bleeding or air will enter master cylinder requiring more extensive bleeding.
    ⚠Bleeder screws are easily stripped. Use proper size wrench and do not exceed specified torque.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Repeat for opposite side
    Repeat steps 1-11 for the opposite rear caliper. Maintaining consistent procedure ensures both calipers are properly rebuilt and bled.
13. 13

    Final system bleeding
    After both rear calipers are rebuilt and initially bled, perform complete brake system bleeding starting from wheel furthest from master cylinder (usually right rear, then left rear, then right front, then left front). This ensures all air is purged from system. Top off brake fluid reservoir to MAX line with fresh DOT 4 brake fluid and reinstall cap.
14. 14

    Reinstall wheels and test
    Reinstall rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground and torque lug nuts to specification in star pattern. Pump brake pedal multiple times until firm pedal is achieved. Check brake fluid level and inspect all connections for leaks.
    ⚠️DO NOT drive vehicle until firm brake pedal is achieved and verified. Soft or spongy pedal indicates air in system or other problems requiring immediate attention.
    Torque spec

    Wheel Lug Nuts190 Nm (140 lb-ft)

Reassembly

1. Ensure all bleeder screws are closed and torqued properly
2. Verify brake fluid reservoir is filled to MAX line with fresh DOT 4 fluid
3. Check all brake line connections for signs of leakage
4. Verify caliper slide pins move freely and are properly lubricated
5. Ensure wheels are torqued properly in star pattern

Verification

• Pump brake pedal multiple times - pedal must become firm and hold pressure without slowly sinking
• With engine running, apply firm brake pressure and verify pedal does not sink to floor
• Inspect all brake connections, calipers, and lines for any signs of fluid leakage
• Test drive vehicle in safe area at low speeds (under 15 mph) to verify brakes engage properly and evenly without pulling
• Perform several moderate brake applications to seat pads and verify proper operation
• After test drive, recheck brake fluid level and inspect for leaks again
• Verify brake pedal feel remains firm and consistent
• If any abnormality is detected (soft pedal, pulling, noise, leaks), do not drive vehicle and seek professional service immediately

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