How to Replace the Calipers on a '97 Chevy Suburban

The Chevrolet Suburban was introduced in 1936. The 1997 Chevrolet Suburban was manufactured in more than seven sub-models between the 1500, 2500, and 3500 series. The 1997 Suburban was equipped with the option of eight different engines, depending upon the sub-model and size of the Suburban. The 1997 Suburban was produced with standard ventilated front disc brakes, and rear drum brakes. The front disc brakes incorporate the use of calipers, rotors, pads, and the front brake hoses. Replacing the calipers will take approximately 1 1/2 to 2 hours per side depending on whether you have done this type of work before.

Instructions

Remove the torque from the front wheel lug nuts using a tire iron. Lift the front of the Suburban with a 2-ton jack or a jack with greater capacity. Place jack stands beneath the front frame rails of the Suburban to support the truck during this project. Remove the lug nuts completely from the wheels, then remove the wheels from the Suburban.

Place a brake hose clamp or needle-nose vice grips on the small rubber hose that leads from the back of the brake caliper to the frame of the truck. The brake caliper is the large metal part wrapped around the large metal disc or brake rotor. Place the clamp as close to the back of the caliper as possible to eliminate loss of brake fluid during the caliper replacement. Remove the caliper mounting bolts from the back of the caliper using a 3/8-inch drive ratchet and socket. Turn the bolts counter-clockwise until you can remove them by hand.

Remove the brake line bolt from the rear of the brake caliper using an open-end line wrench. Turn the brake line bolt counter-clockwise until it is removed from the rear of the caliper. Remove the brake caliper from the brake assembly by hand, using a small pry bar or large flat-head screwdriver to pry the caliper loose if necessary. Remove the brake caliper from the Suburban.

Install the new brake caliper over the pads and rotor assembly, in the same position as the old caliper. The brake bleeder screw should be facing the rear of the caliper and on the top end of the caliper. This is how you differentiate between the left and right calipers. Install the caliper mounting bolts into the rear of the caliper, and tighten the caliper bolts to 35 foot-pounds using a certified torque wrench and socket. Do not guess on your torque strength by using a standard ratchet.

Install the brake hose and brake hose bolt into the rear of the new caliper. Tighten the hose bolt until it is snug, and then turn the bolt 1/4-turn farther. This is known as the "snug-and-a-quarter" method of tightening a bolt. This method is used when you do not need to torque a bolt or torquing the bolt will damage parts. Use a standard ratchet and socket to perform the tightening procedure on the brake line bolt.

Perform steps 2 through 5 to complete the caliper replacement on the second side of the Suburban, then continue to the next section of this project.

Ask your assistant to sit in the driver's seat of the Suburban. Instruct him to use the word "up" when the brake pedal is at its top resting position or pumped to a desired back pressure level. Instruct your assistant to use the words "down and holding" when he/she is holding the brake pedal to the floor of the truck. This communication process should eliminate any errors during the brake bleeding process.

Place a line wrench onto one of the brake bleeder screws. Open the screw by turning it counter-clockwise with a wrench. Ask your assistant to push the brake pedal to the floor and hold it there, using the communication cues above. When the pedal is completely to the floor, tighten the bleeder screw immediately to close the screw.

Ask your assistant to pump the brake pedal at least 10 times, then let the pedal go to its upward resting position. Open the bleeder screw again, and instruct your assistant to push the pedal down. Tighten the bleeder screw when you hear the words "down and holding." Repeat steps 2 and 3 of the bleeding procedure at least three times on each side of the Suburban. Inspect and fill the brake fluid reservoir while switching between sides of the truck. One pint of standard brake fluid should be more than enough for the entire bleeding procedure.

Ask your assistant to pump the brake pedal no less than 10 times and hold the brake pedal firm. Open the bleeder screw when you hear the word "up." You should see nothing but brake fluid coming from the rear of the caliper, instead of brake fluid and air pockets. If you see or hear no air pockets, ask your assistant to push the caliper to the floor. Tighten the bleeder screw completely when you hear the words "down and holding." Repeat this step exactly on the other side of the truck to complete the brake bleeding process.