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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 565 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE PADS REPLACEMENT - REARINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation 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.
  1. Using a C-clamp, bottom the piston into the caliper bore. Use an old brake pad or wooden block across the face of the piston. Do not damage the piston or the caliper boot.
    2. Fig 1: Exploded View Of Rear Brake Caliper Components
    GM176945Courtesy of GENERAL MOTORS CORP.
  2. Install the two retainer slides (11) to the caliper bracket.
    3. IMPORTANT: The wear sensor is on the outside pad. The sensor is positioned at the trailing or downward edge of the pad during forward wheel rotation.
  3. Install the pads (9,10) to the caliper bracket (12).
    4. NOTE: Use care to avoid damaging pin boot when rotating caliper.
  4. Remove the support and reposition the caliper (15) back down over the front pads.
  5. Lubricate the bolt and the bolt boot.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the upper caliper bolt.

    Tighten:  Tighten the caliper bolt to 45 N.m (33 lb ft).

  7. Remove the two wheel lug nuts retaining the rotor to the hub.
  8. Install the tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  9. Lower the vehicle.
  10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  11. Slowly release the brake pedal.
  12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  13. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  14. Burnish the pads and rotors. Refer to Burnishing Pads and Rotors .
RENDER: 1.0x

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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.