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Old 10-18-2015, 11:49 PM   #19
BigRed76
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Join Date: Jan 2010
Location: Loveland, CO
Posts: 1,921
Re: Need help with rear disc swap

Update time. I spent some more time on the truck this weekend. I installed the Wilwood 2.38" calipers, using the my existing D52 style pads and the same astro van rotors. After the initial install I gravity bled the rears, then manually bled them to surprisingly find that the pedal still goes to the floor with vacuum assist. I then bled the fronts just to be safe, with no change. I then removed the master cylinder and bench bled it again, which resulted in no change after reinstalling it and bleeding all 4 wheels again. I pinched off the rear axle brake hose and then had a firm pedal, with vacuum assist. So after carefully double checking everything on the rear, and bleeding them again, I noticed that the right rear caliper was moving a considerable amount when the pedal was pressed, whereas the left rear caliper had no noticeable movement. After looking closer at the right rear I found that the caliper and pads are not parallel with the rotor. On top of that the right rear axle seal is leaking...again. That seal has now been replaced twice, and the truck hasn't been driven more than 5 miles since I put in the last seal. So after verifying that the caliper brackets are fully seated against the right rear axle flange, and the rotor is fully seated against the axle, I'm thinking my axle housing may be bent.

So to ensure that my pedal feel issue was related to the pads not being parallel with the rotors I removed the right rear caliper bolts and just let the caliper sit in the bracket so that when the pedal was pressed it would allow the pads to apply parallel against the rotor. Doing this made the pedal considerably stiffer as I thought it would.

Now, I have no idea how the axle housing could've gotten bent, but I do know that right rear axle seal has been leaking since I got the truck 3 years ago. So I think for now i'll try to find another 12 bolt 3.73 axle, although eventually id like to swap in a 9".
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Zach

1970 Chevrolet Custom Camper K20
1971 GMC Super K2500, 12V/NV4500 swap in progress
1971 Chevrolet Custom C10
1972 Chevrolet Custom Deluxe C20, 5.3/4L60E
1972 Oldsmobile Cutlass Supreme, 455/TH400, 3.73 posi
2004 GMC Sierra 2500HD, LB7/Allison, CCSB
2005 GMC Sierra 1500, 5.3/4L60E, CCSB

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