Hummer H2. Manual — part 792

Fig. 16: Removing/Installing Brake Hose Bolt From Brake Caliper (Rear)
Courtesy of GENERAL MOTORS CORP.

Installation

1.

If you are installing NEW brake pads use a C-clamp in order to compress the pistons to the bottom of the
caliper bores. Use the old brake pad, a metal plate or a wooden block across the face of the pistons in
order to protect the pistons and the caliper boots.

2.

Ensure that the caliper boots are below the level of the face of both pistons. Install the brake caliper to the
brake caliper mounting bracket.

NOTE:

Use denatured alcohol to clean the outside surface of caliper boots before
installing NEW brake pads.

NOTE:

Use a small flat-bladed tool and lift the inner edge of the caliper boots next
to both pistons to release any trapped air. See Fig. 17 .

2004 Hummer H2

2003-04 BRAKES Disc - Hummer

3. Perform the following procedure before installing the caliper guide pin bolts.

z

Remove all traces of the original adhesive patch.

z

Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.

z

Apply Threadlocker (GM P/N 12345493) to the threads of the bolt.

4. Install the brake caliper mounting bolts. See Fig. 25 . Tighten the brake caliper guide pin bolts to

specification. See TORQUE SPECIFICATIONS . Remove the rubber cap or plug from the exposed
brake hose fitting end.

5.

Assemble the 2 NEW copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.

6. Connect the brake hose at the caliper by installing the brake hose to caliper bolt. See Fig. 16 . Tighten the

brake hose to caliper bolt to specification. Bleed the hydraulic brake system. See BLEEDING BRAKE
SYSTEM .

7. Install the tire and wheel assembly. Lower the vehicle. Fill the master cylinder reservoir to the proper

level with clean brake fluid.

NOTE:

Install 2 NEW copper brake hose gaskets.

2004 Hummer H2

2003-04 BRAKES Disc - Hummer

Fig. 17: Releasing Trapped Air From Caliper Boots
Courtesy of GENERAL MOTORS CORP.

BRAKE CALIPER BRACKET

CAUTION: Avoid taking the following actions when you service wheel brake parts:

DO NOT grind brake linings. DO NOT sand brake linings. DO NOT clean
wheel brake parts with a dry brush or with compressed air. 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.

2004 Hummer H2

2003-04 BRAKES Disc - Hummer

Removal (Front)

1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire or

equivalent. DO NOT disconnect the hydraulic brake flexible hose from the caliper.

2. Remove the brake pads. See BRAKE PADS . Remove the anti-rattle clips from the brake caliper bracket.

Remove the brake caliper bracket mounting bolts. See Fig. 18 . Remove the brake caliper bracket.

3. Remove any contaminants or foreign material from the inside ends of the brake caliper bracket. Clean the

mounting surface and threads of the brake caliper bracket.

NOTE:

Support the brake caliper with heavy mechanic's wire, or equivalent, whenever
it is separated from it's mount and the hydraulic flexible brake hose is still
connected. Failure to support the caliper in this manner will cause the flexible
brake hose to bear the weight of the caliper, which may cause damage to the
brake hose and in turn may cause a brake fluid leak.

2004 Hummer H2

2003-04 BRAKES Disc - Hummer