Hummer H2. Manual - part 791

Removal (Front) 

1. Inspect the fluid level in the brake master cylinder reservoir. If the brake fluid level is midway between 

the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the 
reservoir before proceeding.  

2. If the brake fluid level is higher than midway between the maximum-full point and the minimum 

allowable level, remove brake fluid to the midway point before proceeding. Raise and support the vehicle. 
Remove the tire and wheel assembly.  

3. Compress the brake caliper pistons. Install a large C-clamp over the top of the caliper housing and against 

the back of the outboard pad. See Fig. 14 . Slowly tighten the C-clamp until the pistons are pushed 
completely into the caliper bores. Remove the C-clamp from the caliper.  

4.  

Clean all dirt and foreign material from the brake hose end. Remove the brake hose to caliper bolt from 
the brake caliper. See Fig. 15 . Remove and discard the 2 copper brake hose gaskets. These gaskets may 
be stuck to the brake caliper housing or the brake hose end. Remove the brake hose from the caliper.  

5.  

Remove the 2 brake caliper mounting bolts. See Fig. 25 . Remove the brake caliper from the brake caliper 
mounting bracket.  

NOTE:

Install a rubber cap or plug to the exposed brake pipe fitting end to 
prevent brake fluid loss and contamination. 

CAUTION: DO NOT depress the brake pedal with the brake rotors/calipers 

and/or the brake drums removed. Damage to the brake system may 
result. If brake system damage occurs and is not repaired, vehicle 
damage and/or personal injury or death may result. 

 

2004 Hummer H2 

2003-04 BRAKES Disc - Hummer

  

Fig. 14: Removing Brake Caliper (Front Shown, Rear Similar) 
Courtesy of GENERAL MOTORS CORP.

 

2004 Hummer H2 

2003-04 BRAKES Disc - Hummer

  

Fig. 15: Removing/Installing Brake Hose Bolt From Brake Caliper (Front) 
Courtesy of GENERAL MOTORS CORP. 

Installation 

1. Install the brake caliper to the brake caliper mounting bracket.  

2. 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.  

3. Install the brake caliper guide pin bolts. Tighten the brake caliper guide pin bolts to specification. See 

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

 

2004 Hummer H2 

2003-04 BRAKES Disc - Hummer

  

end.  

4.  

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

5. Bleed the hydraulic brake system. See BLEEDING BRAKE SYSTEM .  

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

level with clean brake fluid.  

Removal (Rear) 

1. Inspect the fluid level in the brake master cylinder reservoir. If the brake fluid level is midway between 

the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the 
reservoir before proceeding.  

2. If the brake fluid level is higher than midway between the maximum-full point and the minimum 

allowable level, remove brake fluid to the midway point before proceeding. Raise and support the vehicle. 
Remove the tire and wheel assembly.  

3. Compress the brake caliper pistons. Install a large C-clamp over the top of the caliper housing and against 

the back of the outboard pad. See Fig. 14 . Slowly tighten the C-clamp until the pistons are pushed 
completely into the caliper bores. Remove the C-clamp from the caliper.  

4. Clean all dirt and foreign material from the brake hose end. Install a rubber cap or plug to the exposed 

brake pipe fitting end to prevent brake fluid loss and contamination. Remove the brake hose to caliper 
bolt from the brake caliper. See Fig. 16 .  

5. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper 

housing or the brake hose end. Remove the brake hose from the caliper.  

6. Remove the caliper guide pin bolts. See Fig. 25 . Remove the brake caliper from the vehicle. Inspect the 

caliper assembly.  

NOTE:

Install 2 NEW copper brake hose gaskets. 

 

2004 Hummer H2 

2003-04 BRAKES Disc - Hummer