How to Replace 1999 Chevy Tahoe Brake Rotors

The 1999 Chevy Tahoe replaced the old full-sized Chevy Blazer. Smaller than a Suburban, the Tahoe features a front disc braking system and may have rear disc or rear drum brakes. When replacing the rotors, you should also consider replacing the pads and servicing the caliper. New pads would offer a friction composition to mate to the surface of the new rotor. Although machining the rotor may be an option to remove any warping or run-out, replacing the rotor is advised.

Instructions

Remove 1/3 of the brake fluid from the master cylinder using a hand pump. Be sure the hand pump has never been used on a petroleum-based product before to avoid contaminating the hydraulic brake fluid; otherwise brake failure can occur. Discard the old fluid and replace the master cylinder cap.

Raise the front axle using a jack, and support the Tahoe onto jack stands. Never support the vehicle with a jack alone. Remove the front lug nuts using an impact gun and impact socket, then remove the wheels.

Place the C-clamp over the outboard pad and caliper, and then tighten to compress the caliper piston fully into the bore. Remove the clamp.

Remove the caliper and mounting bracket as an assembly if you're replacing the pads. To do so, the mounting bracket bolts need to be removed with a hand wrench or ratchet and socket, then the assembly needs to be removed from the brake rotor. Support the brake rotor to the suspension so it does not hang from the brake hose and cause damage to it.

Remove the rotor. If the rotor is rusted or corroded to the hub, spray penetrating oil along the hub and lug studs where the rotor and hub mate, and allow a few minutes to soak in. Insert the two 10-mm by 1.5-mm jack screws into the two small screw holes on the hub face of the rotor, then tighten them alternately a couple turns each using a ratchet and a socket until the rotor separates from the hub.

Clean the mating surface of the hub using an emery cloth to remove any rust or corrosion buildup. Clean the surface and vents of the new rotor with a spray brake clean solvent to remove the rust preventive coating. Allow it to air dry, or use a shop rag to wipe it dry. Be sure to spray both sides.

Place the new rotor onto the hub and the caliper assembly over the rotor. Hold the caliper assembly in place while aligning the caliper bracket bolts into their respective holes. Tighten the caliper brackets with a torque wrench and socket to 110 foot pounds.

Replace the wheel and lug nuts. Tighten the lug nuts to 130 foot pounds using a torque wrench and socket. Repeat the procedure for the other side.

Once the wheels are replaced on the Tahoe and it is lowered to the ground, pump the foot brake several times until it is firm. Check and adjust the level of brake fluid in the master cylinder. Add brake fluid if necessary.