How to replace the front brake rotors on your 2006 Chevrolet Silverado 2500

The brakes on a 2006 Chevy Silverado 2500 or 3500 have parts in them that need to be replaced over time to maintain the integrity of the brakes. Check and replace parts as needed. The brakes may give off a dust that can contain asbestos or other contaminants, so caution should be taken when working with brake parts that have dust on them. Dust can be eliminated or reduced by using a wet cloth or a commercial cleaner to wipe them down.

Additionally, avoid grinding brake linings, sanding brake linings and cleaning the wheel brake parts with any compressed air or a dry brush. There are special tools that are recommended in order to complete the job. J 41013 is a cleaning disc to resurface the rotor and J 42450-A is a wire cup for wheel hub resurfacing.

Removing the Brake Rotor

Park on a flat, dry surface and jack up the Silverado using the proper jacks and jack stands. Use caution when lifting the vehicle and make sure it is properly set before continuing with the rotor removal, and follow these steps:

  1. Using proper tire and wheel removal procedures, take them both off the truck. On dual wheel vehicles, you need to remove the front wheel hub extension.
  2. Place a large screwdriver into a brake rotor vane by going through the brake caliper to keep the rotor steady
  3. Mark the relationship of the hub to the front wheel hub extension.
  4. Take the front wheel hub extension nuts and extension off the vehicle
  5. In the brake master cylinder reservoir, look at the fluid level. You do not need to remove fluid in order to continue if it is between the maximum and minimum allowable points. If necessary, remove enough fluid to get you to the midway point.
  6. Mark the relationship of the hub to the rotor.
  7. Compress the pistons on the brake calipers. Place two large C-clamps over the caliper housing and the back of the outboard pad. Tighten the clamps slowly until the pistons are completely pushed within the caliper bores. Remove the C-clamps.

While the caliper and hose are disconnected from the mount, use heavy wire to support it or you risk damaging the hose.

  1. Take the caliper bracket and caliper off as one piece, and support it.
  2. If you have brake rotor retaining push nuts, remove them from the wheel studs.
  3. Take off the brake rotor. If it is corroded, you may need to do a little extra work to get it removed. A generous application of penetrating oil should be added to the hub rotor area to clean it. Place two M10 x 1.5 jackscrews or bolts into the rotor's threaded holes. Then tighten those bolts in an even manner that will help force the hub and rotor apart.

Installing the Brake Rotor

While you have the brake rotor separated, clean any rust or contamination from the hub/axle flange. This will avoid problems with lateral run-out and brake pulsation. Use J 42450-A to clean the hub flange and J 41013 to clean the inside diameter. Make sure the mating surfaces are clean of debris. If there are nicks or marks that are raised, be sure they are removed before you install the rotor. If applicable, align the hub and rotor to an original position. Then install your rotor.

Replace the caliper and bracket.

Before you install the caliper bracket bolts, make sure you remove all pieces of the original adhesive patch, and clean the bolt threads with a cleaner made for brake parts and let it dry. Use a threadlocker to lock the threads of the bolt. (GM P/N 12345493) Fasteners must be used correctly to protect against damage. Use only approved sealants or thread locking compounds.

  • Install and tighten the brake caliper bracket bolts using 221 lb ft (300 Y).
  • On dual wheel vehicles, reinstall the front wheel hub extension.
  • Take a large screwdriver and place it through a brake rotor vane and brake caliper to keep it stationary.
  • Replace the front wheel hub extension to the original hub position. Tighten in the same sequence used on an 8-lug wheel.
  • Add the nuts for the front wheel extension, and tighten them to 96 lb ft (130 Y).
  • Reinstall the wheel assembly and tire.
  • Keep the engine turned OFF, and with your foot slowly apply pressure to the brake pedal until it is close to 2/3 down.
  • Slowly release the pedal. Repeat every 15 seconds until the pedal is firm. This seats the pads and caliper pistons. Burnish the rotor and brake pads if you replaced or refinished the rotor.

You are now equipped with the instructions on changing the front rotor in your 2006 Chevy Silverado 2500 or 3500.

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