Hummer H1 (2006+). Manual — part 234

7-18

Brake System

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2.

Disconnect the brake line from the the ABS modulator assembly.

3.

Remove the capscrew and clamp securing the brake line to the crossmember, and remove the brake line (Figure 7-11).

4.

Reverse the removal procedure for installation and bleed the brake hydraulic system.

Figure 7-11: Front Brake Line Replacement

Intermediate Brake Line Replacement

NOTE: The procedure is the same for the right and left intermediate brake lines.

1.

Disconnect the intermediate brake line from the ABS modulator assembly.

2.

Disconnect the intermediate brake line from the rear brake line at the union located forward of the forward-rear crossmember.

3.

Remove the capscrews and clamps securing the intermediate brake line to the frame rail and remove the brake line from the
vehicle.

4.

Reverse the removal procedure for installation and bleed the brake hydraulic system.

Rear Brake Line Replacement

Removal

1.

Disconnect the rear brake line from the caliper.

2.

Disconnect rear brake line from the intermediate brake line at the union located forward of the forward-rear crossmember
(Figure 7-12).

CLAMP

CROSSMEMBER

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Brake System 7-19

5745804

Figure 7-12: Rear Brake Line Replacement

3.

Remove the capscrew and clamp securing the rear brake line to the forward-rear crossmember and remove the brake line from
the vehicle.

4.

Reverse the removal procedure for installation and bleed the brake hydraulic system.

Figure 7-13: Rear Brake Component Location

UNION

INTERMEDIATE

LINE

REAR

LINE

METAL
BRAKE

LINES

CALIPER

FROM

ABS/TT4

MODULATOR

LINE

MOUNTING

CLIP

UNION

7-20

Brake System

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Figure 7-14: Front Brake Component Location

SERVICE BRAKE PEDAL REPLACEMENT

Removal

1.

Disconnect the stoplight switch (Figure 7-15).

2.

Remove the pushnut and disconnect the stoplight switch rod (if so equipped) from the brake pedal assembly. Discard the
pushnut. (Figure 7-15).

3.

Disconnect the return spring from the brake pedal assembly.

4.

Remove the cotter pin and washer securing the hydro-boost pushrod to the brake pedal bellcrank, and disconnect the hydro-
boost pushrod from the brake pedal bellcrank. Remove the spring washer. Discard the cotter pin and spring washer.

5.

Remove the nut, two washers, pivot pin, and brake pedal assembly from the bracket.

CALIPER

MASTER CYLINDER

HYDROBOOST

METAL
BRAKE

LINES

LINE

MOUNTING

CLIP

METAL LINES

TO REAR CALIPERS

ABS

MODULATOR

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Brake System 7-21

5745804

6.

Remove the two bushings from the brake pedal assembly. Discard the two bushings.

Installation

1.

Apply silicone grease to the inside of the two bushings. Install the two bushings in the brake pedal assembly.

2.

Install the brake pedal assembly on the bracket with the pivot pin, two washers, and the nut. Using the adapter and a crowfoot,
tighten the nut to 60 lb-ft (81 N•m).

3.

Install the spring washer on the brake pedal bellcrank. Connect the hydro-boost pushrod to the brake pedal bellcrank with the
washer and new cotter pin.

4.

Connect the return spring to the brake pedal assembly.

5.

Use the pushnut to install the stoplight switch rod (if so equipped) to the brake pedal assembly.

6.

Connect the stoplight switch.

7.

Operate the vehicle and check the brakes for proper operation.

8.

Check the brake lights for proper operation.

Figure 7-15: Service Brake Pedal Components

SERVICE BRAKE ROTOR REPLACEMENT

Removal

1.

Remove the service brake caliper.

2.

Remove the six capscrews, lockwashers, halfshaft, and rotor from the output flange. Discard the ockwashers (Figure 7-17).

Installation

1.

Apply high strength thread-locking compound to the threads of the capscrews if the original capscrews are used.

2.

Install the rotor on the output flange.

3.

Secure the halfshaft and rotor to the output flange with twelve inclined cam lockwashers and 6 capscrews with preapplied
threadlocker. Tighten the capscrews to 57 lb-ft (77 N•m).

4.

Install the service brake caliper.

PIVOT PIN

STOPLIGHT

BRACKET

BUSHING

BRAKE PEDAL

BRAKE PEDAL

HYDRO-BOOST

RETURN SPRING

PUSHROD

BELLCRANK

ASSEMBLY

STRIKER

SPRING

SWITCH

WASHER