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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 565 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE CALIPER OVERHAUL - FRONTASSEMBLY PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Assembly Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Assembly Procedure
WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Inspecting Brake Caliper Bore
    GM177058Courtesy of GENERAL MOTORS CORP.
  1. Install the bleeder valve and the bleeder valve cap to the caliper housing.
  2. Install a new lubricated piston seal (4) to the caliper bore grooves. Ensure that the piston seal is not twisted.
    3. Fig 2: Inspecting Brake Caliper Bore
    GM177051Courtesy of GENERAL MOTORS CORP.
  3. Install the lubricated boot (1) onto the brake caliper piston (2).
  4. Lubricate the brake caliper piston (2) with clean brake fluid.
  5. Install the brake caliper piston and the brake caliper piston boot into the bore of the caliper. Push the brake caliper piston to the bottom of the bore.
    6. Fig 3: Identifying J 36349
    GM717654Courtesy of GENERAL MOTORS CORP.
  6. Seat the caliper boot in the caliper housing counterbore using the J 36349 .
  7. Install the caliper. Refer to Brake Caliper Replacement - Front .
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.