1995 Chevrolet K2500 Pickup Brake Service (ONLINE REPAIR MANUALS)

Astro & Safari

• Disconnect master cylinder from power brake unit.
• Disconnect power brake unit pushrod from brake pedal.
• Remove power brake unit retaining nuts and the power brake unit.
• Reverse procedure to install.

Full Size Except C & K Series

• Remove master cylinder attaching nuts and position master cylinder aside. Do not disconnect brake lines from cylinder.
• Disconnect power brake unit pushrod from brake pedal.
• Remove attaching nuts, then the power brake unit.
• Reverse procedure to install.

S/T Series & Bravada

• Disconnect master cylinder assembly and vacuum hose from power br...

Certain general service procedures apply, regardless of whether the brakes are vacuum or hydraulically assisted. Only top quality, clean brake fluid should be used. More seals and valves are used with power brake systems than with ordinary brakes, so an inferior brake fluid will do much more damage. For the same reason, be sure all dirt is kept out of the system. Additionally, care must be taken not to mix the fluids of the booster hydraulic system and brake hydraulic system as the fluids are not compatible.

If the power unit fails, the brakes will still operate, as the conventio...

In order to properly service power brake systems, a thorough understanding of the power assist system is necessary. These systems provide a mechanical assist, acting to increase the force applied to the master cylinder piston by the driver while decreasing the effort necessary to obtain acceptable stopping performance.

Hydraulic assist units incorporate a basic open center spool valve, hydraulic cylinder and an accumulator assembly in a common housing. When the brake pedal is depressed, the hydraulic piston moves forward closing off fluid relief passages, the spool valve applies flui...

Master Cylinder

Some vehicles use a conventional tandem master cylinder with two hydraulic pistons operating inline. The primary piston controls the front brake system and the secondary piston controls the rear brake system.

Other models use a master cylinder that operates the same as the conventional master cylinder, but also incorporates a quick take-up feature in the rear chamber to reduce excessive pedal travel which may result from increased fluid displacement required to move the low drag caliper piston out against the rotor.

The quick take-up uses a spring-loaded ball check valv...

Brake System Bleed

1992

Before bleeding the brakes, the front and rear displacement cylinder pistons must be returned to the top most position. Using a TECH 1 or equivalent scan tool, enter manual control function and apply the front and rear motors. Ensure enable relay is on.

Use only DOT 3 brake fluid from a clean and sealed container. Do not use DOT 5 brake fluid.

Pressure Bleeding

• Remove master cylinder cover, ensure reservoir is properly filled.
• Connect bleeder adapter tool No. J 35589, or equivalent, to master cylinder reservoir.
• Connect bleeder adapter to pressure bleeding equipm...

• Inspect components for damage or unusual wear. Replace as necessary.
• Inspect backing plate attaching bolts, and ensure they are tight.
• Inspect wheel cylinders. Excessive fluid indicates cup leakage and need for wheel cylinder replacement. A slight amount of fluid is always present and is considered normal, act...