Hummer H2. Manual — part 781

Fig. 4: Identifying Brake Caliper Assembly Components
Courtesy of GENERAL MOTORS CORP.

2004 Hummer H2

2003-04 BRAKES Disc - Hummer

BRAKE PAD INSPECTION

z

If replacement is necessary, always replace disc brake pads in axle sets. See BRAKE PADS under
REMOVAL & INSTALLATION.

z

Inspect both edges of the disc brake pad friction surfaces. The highest rate of wear normally occurs at the
trailing edge of the disc brake pads.

z

Inspect the thickness of the disc brake pads in order to ensure that they have not worn prematurely. The
disc brake pad wear should be approximately even per axle set.

z

Both front and rear disc brake pads have integral, audible wear sensors. See Fig. 5 . When the disc brake
pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor. The
wear indicator will then produce an audible, high-pitched warning noise during wheel rotation.

z

Replace the disc brake pads when the friction surface is worn to within 0.03" (0.76 mm) of the mounting
plates. See BRAKE PADS under REMOVAL & INSTALLATION.

z

Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to
ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between
the surfaces. If more than 0.005" (0.13 mm) gap exists midway between the length of the disc brake pads,
replace the disc brake pads. See BRAKE PADS under REMOVAL & INSTALLATION.

z

Verify that any disc brake pad shims that may be required are in place and not damaged or excessively
corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance.

z

Replace the disc brake pads if any have separated from the mounting plates. See BRAKE PADS under
REMOVAL & INSTALLATION.

z

Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or
otherwise impair disc brake performance.

WARNING:

Avoid grinding brake linings, sanding brake linings or cleaning wheel
brake parts with a dry brush or with compressed air, when servicing
wheel brake parts. Some models or aftermarket brake parts may contain
asbestos fibers which can become airborne in dust. Breathing dust with
asbestos fibers may cause serious bodily harm. Use a water-dampened
cloth in order to remove any dust on brake parts. Equipment is available
commercially in order to perform this washing function. These wet
methods prevent fibers from becoming airborne.

NOTE:

Inspect the disc brake pads at regular intervals, or whenever the tire and wheel
assemblies are removed from the vehicle.

2004 Hummer H2

2003-04 BRAKES Disc - Hummer

Fig. 5: Inspecting Brake Pad
Courtesy of GENERAL MOTORS CORP.

2004 Hummer H2

2003-04 BRAKES Disc - Hummer

BRAKE PEDAL PUSHROD INSPECTION

1. Disconnect the brake pedal pushrod from the brake pedal.

2. Inspect the brake pedal pushrod eyelet bushing for cracks and/or excessive wear. See Fig. 6 .

3. Reposition the pedal pushrod boot toward the front of the vehicle to expose as much of the pedal pushrod

as possible.

4. Inspect the brake pedal pushrod for straightness.

5. If the brake pedal pushrod eyelet bushing exhibited cracks and/or excessive wear, then the bushing

requires replacement.

6. If the brake pedal pushrod is not straight, then the pushrod requires replacement. Return the pedal

pushrod boot to its original position on the pedal pushrod.

7. Connect the brake pedal pushrod to the brake pedal.

Fig. 6: Inspecting Brake Pedal Pushrod
Courtesy of GENERAL MOTORS CORP.

BRAKE PIPE & HOSE INSPECTION

WARNING:

Brake fluid may irritate eyes and skin. In case of eye contact, rinse

2004 Hummer H2

2003-04 BRAKES Disc - Hummer