130522001 Service Bulletin/Repair Instructions

File in Section:

Bulletin No.:
Service Bulletin
Date:
05 - Brakes

13-05-22-001

November, 2013
INFORMATION

Subject:
Pre-Formed and Pre-Flared Hydraulic Brake Pipe Kits Now Available for Service
Models:
2000-2006 Cadillac Escalade Models

2000-2006 Chevrolet Avalanche, Suburban, Tahoe

1999-2007 Chevrolet Silverado

2000-2006 GMC Yukon Models

1999-2007 GMC Sierra
The purpose of this bulletin is to inform dealers of an

improved service strategy to aid in the replacement of

hydraulic brake pipes for the above listed vehicles.

Customer Care and Aftersales (CCA) has released

pre-formed and pre-flared hydraulic brake pipe kits.

These kits can be used anytime replacement of the

entire brake pipe assemblies is required. These kits

include all the pre-formed and pre-flared brake pipes

needed when replacing the entire brake pipe assembly,

except the rear axle crossover pipe. If the rear axle

crossover pipe requires replacement, refer to the

appropriate parts catalog for ordering and the Brake

Pipe Replacement procedure in SI for installation

instructions. The following procedure describes how to

install these kits.
Replacement Procedure (Pickup and

Cab Chassis)

Removal

Warning: Brake fluid may irritate eyes and skin. In

case of contact, take the following actions:

• Eye contact—rinse thoroughly with water.

• Skin contact—wash with soap and water.

• If ingested—consult a physician immediately.

Caution: Avoid spilling brake fluid onto painted

surfaces, electrical connections, wiring, or cables.

Brake fluid will damage painted surfaces and cause

corrosion to electrical components. If any brake fluid

comes in contact with painted surfaces, immediately

flush the area with water. If any brake fluid comes in

contact with electrical connections, wiring, or cables,

use a clean shop cloth to wipe away the fluid.

Caution: Care should be taken to ensure that dirt,

water, grease, or other contaminants do not enter the

new brake pipes and threaded end fittings when the

pipes are being installed into the vehicle. Use tape or

other appropriate methods to cover the threaded end

fittings and the ends of the pipes to prevent dirt, water,

grease, or other contaminants from entering the pipes.

Remove all protective measures before connecting the

end fittings to the master cylinder, brake pressure

proportioning valve (where equipped), brake pressure

modulator valve (BPMV), or flexible brake hoses.

Copyright 2013 General Motors LLC. All Rights Reserved.
Caution: Cleanliness is important for the proper

function of the hydraulic brake system. Clean all dirt,

water, rust, etc from the areas adjacent to each brake

pipe tube nut before removing the brake pipe tube nuts.

Take care to ensure that no contaminants enter any

hydraulic fittings or openings during removal or

installation of the brake pipes.

Caution: Before removing any brake pipes from the

master cylinder, ABS module (BPMV), and the brake

pressure proportioning valve (where equipped) identify

the port locations. On the BPMV identify the port

location for each hydraulic component (e.g., Master

Cylinder Primary, Master Cylinder Secondary, LF

corner, RF corner, LR corner, RR corner, Rear Brake).

On the brake pressure proportioning valve identify the

port locations for each hydraulic component (e.g.

master cylinder primary inlet, master cylinder primary

outlet, master cylinder secondary inlet, master cylinder

secondary outlet, pre-charge pump). When installing

the replacement pipes, ensure that the replacement

pipes are installed in the correct port locations on the

master cylinder, BPMV, and brake pressure

proportioning valve, where equipped. If the pipes are

not installed in the correct port locations on all the

hydraulic components, the brake system including the

ABS system and/or TCS/VSES Stabiltrak system

(where equipped) will not operate correctly and may

result in damage to the hydraulic brake components.

Note: This procedure does not comprehend specific

vehicle models or brake system configurations. The

illustrations may not exactly reflect the vehicle being

repaired. Some LD pickups and LD SUVs may be

equipped with a brake pressure combination valve and

a brake pressure modulator valve pre-charge pump.

The brake pipes attached to these components should

be removed and replaced with the replacement pipes

provided in the service kit.

Note: This procedure is not intended for the repair or

replacement of a single damaged brake pipe. This

procedure is for the replacement of the entire brake

pipe assemblies with pre-formed and pre-flared

components.

Note: Remove the brake pipes from the existing

routing clips carefully to avoid damaging the clips as all

the clips will be re-used. The new brake pipes will be
Page 2
November, 2013
reinstalled into the existing clips. After installing the

new brake pipes, inspect the routing of the brake pipes

to ensure that the new brake pipes do not contact or

rub on any frame, body, or chassis components.

Carefully bend the pipes to increase clearance as

required.

Note: The brake pipes in these kits are not an exact

duplicate of the pipes currently installed on the vehicle.

These pipes have a nylon coating to provide better

corrosion protection and may have slightly different

shapes and bends and may not exactly match the

brake pipes being replaced. Some original equipment

pipes may use flexible hose sections near the master

cylinder or brake pressure proportioning valve that

attaches to the master cylinder to brake booster

mounting studs. The replacement pipes in this kit will

not use the flexible hose sections. The replacement

pipes have been designed to fit each vehicle

application. Because of the nylon coating on the

outside of the brake pipes, the outside diameter of the

pipe is slightly larger than the original pipes, Extra effort

may be required to insert the pipes into the existing

mounting clips. It is recommended to finger start all the

threaded end fittings into the master cylinder, brake

pressure proportioning valve, brake pressure

modulation valve, and flexible brake hoses before

performing the final tightening and torque of each

fitting.

Note: The brake pipes in these kits may have

additional large radius shipping bends to allow the

pipes to fit within the cardboard box. Those pipes with

additional shipping bends will have tags on either side

of each shipping bend. Carefully straighten the section

of pipe between the tags to remove the shipping bend.

Take care not to kink or damage the brake pipes. If a

brake pipe becomes kinked or damaged while

removing the shipping bends, it must be repaired or

replaced before installation into the vehicle. Take care

not to cut, nick, abrade or otherwise damage the nylon

coating on the brake pipes during installation.

Note: For Chassis Cab models, due to the installation

and mounting of the aftermarket equipment/body on the

rear of the chassis (i.e. flatbed, stake bed, box van,

dump body, etc) by the second stage manufacturer or

vehicle upfitter, it may be difficult or prohibitive to

remove the aftermarket body to enable replacement of

the OEM rear brake pipe. Each vehicle will need to be

assessed individually, however, it may be preferable to

hand bend a service replacement brake pipe using GM

P/N 88936298 PIPE, BRK (STEEL) (1/4" X 16 FT

ROLL) nylon coated bulk tubing available separately

from GM dealers, using GM P/N 15103241 Fitting, BRK

PIPE (1/2-20-2A THD) (1/4 TUBE STL) to attach to the

ABS module (BPMV) and GM P/N 11609443 Tube Nut

(7/16-24 UNS-2A THD) to attach to the rear axle jounce

hose. These tube nuts are designed to properly fit over

the nylon coated brake tubing. The tube nuts can also

be removed from the replacement rear pipe included in

the brake pipe service kit and installed on the hand

bent service replacement pipe. Route the hand bent

service replacement pipe from the ABS module

(BPMV) to the rear axle jounce hose ensuring adequate

clearance is maintained between the pipe and

surrounding components to ensure that the pipe is not
Bulletin No.: 13-05-22-001
damaged in service. Attach the hand bent service

replacement brake pipe securely to the chassis using

brake pipe clips, rubber coated P-clips, or other

suitable methods. The maximum distance between

attachment points or clips should not exceed 457 mm

(18"). If a brake pipe has a directional change (bend) of

30 degrees or more, a clip needs to be located as close

as possible to the bend.
3339728
1. Disconnect the master cylinder secondary (1) and

primary (2) brake pipe fittings from the master

cylinder.

2. Plug the master cylinder outlet ports to prevent

brake fluid loss and contamination.
3339729
3. For vehicles equipped with a combination valve,

disconnect the master cylinder secondary (1) and

primary (2) brake pipe fittings from the combination

valve.
Bulletin No.: 13-05-22-001
November, 2013
4. Plug the combination valve inlet ports to prevent

brake fluid loss and contamination.
Page 3
14. Remove the 3 left side body mount bolts and the

core support mount bolt. Refer to Drivetrain and

Front Suspension Frame Insulator Replacement

in SI.

Note: Only raise the body enough to gain hand

access to the brake pipe routing clips. Pay careful

attention to avoid stressing hoses and wiring

harnesses.

15. Carefully raise the left side of the body from

inboard of the frame rails

approximately 51 mm (2 in).

Note: Place the support blocks inboard of the frame

rails and as close to the body mounting points as

possible to evenly distribute the weight of the

vehicle body.
3339730
5. For vehicles equipped with a combination valve,

disconnect the secondary (1) and primary (2) brake

pipe fittings from the combination valve.

6. Raise and support the vehicle. Refer to Lifting and

Jacking the Vehicle in SI.

7. Remove the front and rear tire and wheel

assemblies. Refer to Tire and Wheel Removal and

Installation in SI.

8. Apply ACDelco Rust Penetrant and Inhibitor

10-4020 (GM P/N 88862628) or equivalent

penetrating lubricant to the bleeder screws of the

following components:

• Front brake calipers

• Rear brake calipers

9. Apply ACDelco Rust Penetrant and Inhibitor

10-4020 (GM P/N 88862628) or equivalent

penetrating lubricant to the brake pipe fitting tube

nuts at the following locations:

• Front brake hoses

• Brake pressure modulator valve (BPMV)

• Rear brake hose(s)

10. Remove the left and right front wheelhouse panels.

Refer to Wheelhouse Panel Replacement in SI.

11. Remove the engine protection shield, if equipped.

Refer to Engine Protection Shield Replacement

in SI.

12. Reference mark the parking brake front cable

adjuster nut at the equalizer and disconnect the

parking brake front cable. Refer to Parking Brake

Front Cable Replacement in SI.

13. Disconnect any wiring ground harnesses from the

body to the frame. Refer to Power and Grounding

Component Views in SI
16. Place blocks or supports inboard of the frame side

rails to support the body in at least 3 locations.

17. Remove the left side pickup box bolts and loosen,

but do not remove, the right side pickup box bolts.

Refer to Pickup Box Replacement in SI.

Note: Only raise the pickup box enough to gain hand

access to the brake pipe routing clips. Pay careful

attention to avoid stressing hoses and wiring

harnesses.

18. Carefully raise the left side of the pickup box

approximately 51 mm (2 in).

Note: Place the support blocks as close to the pickup

box mounting points as possible to evenly distribute the

weight of the vehicle body.

19. Place blocks or supports inboard of the frame side

rails to support the pickup box in at

least 3 locations.

20. Release the body wiring harness conduit from the

brake pipe retainers on the left side of the vehicle.

21. Position and secure the wiring harness aside.
2727389
Page 4
November, 2013
Bulletin No.: 13-05-22-001
22. Using side cutters, cut the right front brake pipe as

close as possible to the brake pipe fitting (1) at the

brake hose.

23. Using a 6 point socket, remove and discard the

right front brake pipe fitting tube nut.

24. Disconnect the left front wheel speed sensor

electrical connector and remove the sensor

harness retaining clips from the top of the left

frame rail.
2728205
27. Release the right front brake pipe from the left front

frame rail clips (1).
2728189
25. Release the right front brake pipe from the

clips (1) on the right frame rail.
2728215
28. Using side cutters, cut the left front brake pipe as

close as possible to the brake pipe fitting (1) at the

brake hose.

29. Using a 6 point socket, remove and discard the left

front brake pipe fitting tube nut.

30. Release the front brake pipes assembly from the

left frame rail clip (2).

2728198
26. Release the right front brake pipe from the front

frame crossmember clips (1).
Bulletin No.: 13-05-22-001
November, 2013
2728220
31. Release the front brake pipes assembly from the

left frame rail clips (1).

32. Clean the area surrounding the brake pipe fittings

on the BPMV thoroughly to remove all dirt and

debris.
3339723
Note: Due to the similarity of the brake pipe fitting tube

nuts, it is imperative to identify the individual brake pipe

locations on the BPMV to ensure correct assembly.

33. Identify the brake pipe port locations at the BPMV

prior to disconnecting the brake pipe fittings.
Page 5
2728225
34. Using side cutters, cut the left front (1) and right

front (2) brake pipes as close as possible to the

brake pipe fittings at the BPMV.

35. Using a 6 point socket, remove and discard the

front brake pipe fitting tube nuts.
2728241
36. Using side cutters, cut the master cylinder

primary (1) and secondary (2) brake pipes as close

as possible to the brake pipe fitting at the BPMV.

37. Using a 6 point socket, remove and discard the

brake pipe fitting tube nuts.

38. Carefully remove the brake pipe routing clips from

the front brake pipe assembly.

39. Maneuver the front brake pipes one at a time and

remove the brake pipes from the vehicle.
Page 6
November, 2013
2728234
40. Using side cutters, cut the rear brake pipe (1) as

close as possible to the brake pipe fitting at

the BPMV.

41. Using a 6 point socket, remove and discard the

brake pipe fitting tube nut.
Bulletin No.: 13-05-22-001
2728259
43. Release the rear brake pipe from the left frame rail

clips (1).
2728497
2728250
42. Release the rear brake pipe from the left frame rail

clips (1).
44. Using side cutters, cut the rear brake pipe (1) as

close as possible to the brake pipe fitting at the

rear brake hose.

45. Using a 6 point socket, remove and discard the

rear brake pipe fitting tube nut.

46. Remove the rear brake pipe from the vehicle.
Installation

Caution: Use the correct fastener in the correct

location. Replacement fasteners must be the correct

part number for that application. Do not use paints,

lubricants, or corrosion inhibitors on fasteners, or

fastener joint surfaces, unless specified. These

coatings affect fastener torque and joint clamping force

and may damage the fastener. Use the correct

tightening sequence and specifications when installing
Bulletin No.: 13-05-22-001
November, 2013
Page 7
fasteners in order to avoid damage to parts and

systems. When using fasteners that are threaded

directly into plastic, use extreme care not to strip the

mating plastic part(s). Use hand tools only, and do not

use any kind of impact or power tools. Fastener should

be hand tightened, fully seated, and not stripped.
2728250
4. Install the rear brake pipe to the left frame rail

clips (1).
2728497
1. Install the rear brake pipe.

2. Install the rear brake pipe fitting tube nut (1).
Tighten

Tighten the nut to 25 Y (18 lb ft)
3339723
Note: Due to the similarity of the brake pipe fitting tube

nuts, it is imperative to identify the individual brake pipe

locations on the BPMV to ensure correct assembly.

5. Connect the brake pipe fittings to the BPMV port

locations identified during removal.
2728259
3. Install the rear brake pipe to the left frame rail

clips (1).
Page 8
November, 2013
Bulletin No.: 13-05-22-001
2728225
6. Install the right front brake pipe fitting tube nut (2).
Tighten

Tighten the nut to 25 Y (18 lb ft)

7. Install the left front brake pipe fitting tube nut (1).
Tighten

Tighten the nut to 25 Y (18 lb ft)
2728241
10. Install the master cylinder primary brake pipe fitting

tube nut (1).
Tighten

Tighten the nut to 25 Y (18 lb ft)

11. Install the master cylinder secondary brake pipe

fitting tube nut (2).
Tighten

Tighten the nut to 25 Y (18 lb ft)
2728234
8. Install the rear brake pipe fitting tube nut (1).
Tighten

Tighten the nut to 25 Y (18 lb ft)

Note: Install the brake pipes to the routing clips and

retaining clips after all the brake pipes are fitted to the

vehicle.

9. Install the master cylinder primary and secondary

brake pipe assembly to the vehicle.
2728220
12. Install the front brake pipes assembly to the left

frame rail clips (1).
Bulletin No.: 13-05-22-001
November, 2013
2728215
13. Install the left front brake pipe fitting tube nut (1).
Tighten
Page 9
2728198
16. Install the right front brake pipe to the front frame

crossmember clips (1).
Tighten the nut to 25 Y (18 lb ft)

14. Install the front brake pipes assembly to the left

frame rail clip (2).
2728189
17. Install the right front brake pipe to the clips (1) on

the right frame rail.

2728205

12 3 4 5 6

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