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HOMESERVICE MANUALSCHEVROLET2003CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 6.0 UREPAIR AND DIAGNOSIS (SINGLE PAGE)BRAKESMECHANICAL - HYDRAULICDISC BRAKESSYSTEM TESTSPARK BRAKE SYSTEM TESTING
2003 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.0 U

Park Brake System Testing

2003 Chevrolet Chevy Express G2500, Van Cargo Extended, 6.0 USECTION Park Brake System Testing
  1. Were you sent here from TROUBLESHOOTING? If so, go to step  4 . If not, go to next step.
  2. Were you sent here from a Park Brake Symptom Table? If so, go to step  4 . If not, go to next step.
  3. Is the symptom related to the ability of the park brake system to hold and/or release? If so, see DIAGNOSTIC STARTING POINT - PARK BRAKE  under TROUBLE SHOOTING. If not, see DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKE  under TROUBLE SHOOTING.
  4. Raise and support the vehicle with the rear axle supported by jack stands. Shift the transmission into Neutral. With the park brake released, attempt to rotate the rear wheels to check the rear brakes for a significant amount of drag. Do the rear brakes have a significant amount of drag? If so, go to step  11 . If not, go to next step.
  5. Shift the transmission into Neutral. Apply the park brake. Attempt to rotate the rear wheels to check the rear brakes for a significant amount of drag. Do the rear brakes have a significant amount of drag? If so, go to next step. If not, go to step  7 .
  6. Release the park brake. Rotate the rear wheels to check the rear brakes for a significant reduction in the amount of drag. Did the rear brakes exhibit a significant reduction in the amount of drag? If so, go to step  22 . If not, go to step  11 .
  7. Visually check the park brake cable connections and the cables that are accessible on the underside of the vehicle for disconnections and/or damage. Were any or the park brake cables disconnected and/or damaged? If so, go to next step. If not, go to step  9 .
  8. Reconnect or replace the park brake cables as necessary. See PARK BRAKE CABLE  under REMOVAL & INSTALLATION. After repairs are complete, go to next step.
  9. Check the adjustment of the park brake. See PARK BRAKE ADJUSTMENT  in PARK BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. Was the park brake adjusted properly? If so, go to step  11 . If not, go to next step.
  10. Adjust the park brake. See PARK BRAKE ADJUSTMENT  in PARK BRAKE SYSTEM under ADJUSTMENTS & INSPECTIONS. Were you able to attain adjustment of the park brake? If so, go to step  16 . If not, go to next step.
    11. WARNING: DO NOT depress the brake pedal with the brake rotors and/or the brake drums removed, or with the brake calipers repositioned away from the brake rotors, or damage to the brake system may result.
  11. Remove the rear brake rotors. See BRAKE ROTORS  under REMOVAL & INSTALLATION. Inspect the park brake shoe hardware for looseness, damaged, broken or missing components. Check the park brake actuators for a seized condition. Does the park brake hardware and/or the park brake actuators require replacement? If so, go to next step. If not, go to step  13 .
  12. Replace park brake hardware components as necessary. See PARK BRAKE SHOE  under REMOVAL & INSTALLATION. Replace the park brake actuators as necessary. See PARK BRAKE ACTUATOR  under REMOVAL & INSTALLATION. After repairs are complete, go to next step.
  13. Have an assistant apply and release the park brake, while you observe the park brake cables for free movement. Did the park brake cables move freely? If so, go to next step. If not, go to step  17 .
  14. Check the adjustment of the park brake. See PARK BRAKE ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS. Was the park brake adjusted properly? If so, go to step  16 . If not, go to next step.
  15. Adjust the park brake. See PARK BRAKE  under ADJUSTMENTS & INSPECTIONS. Were you able to attain adjustment of the park brake? If so, go to next step. If not, go to step  27 .
  16. With the transmission still in Neutral, apply the park brake. Attempt to rotate the rear wheels to check the rear brakes for a significant amount of drag. Release the park brake. Rotate the rear wheels to check the rear brakes for a significant reduction of drag. Did the park brake apply and release properly? If so, go to step  29 .
  17. Disconnect the park brake cable connections that are accessible on the UNDERSIDE of the vehicle one at a time and check each cable for free movement. Do any of the park brake cables accessible on the underside of the vehicle require replacement? If so, go to next step. If not, go to step  19 .
  18. Replace any of the park brake cables that do not have free movement (not releasing properly). See PARK BRAKE CABLE  under REMOVAL & INSTALLATION. After repairs are complete, go to next step.
  19. Disconnect the front park brake cable connection accessible INSIDE the vehicle at the park brake pedal assembly and check for free movement. Replace the front park brake cable if it does not have free movement. See PARK BRAKE CABLE  under REMOVAL & INSTALLATION. Did you find and correct a condition? If so, go to step  25 . If not, go to next step.
  20. Disconnect the park brake release handle assembly cable connection from the park brake pedal assembly and check for free movement. Replace the park brake release handle assembly if the release cable does not have free movement. See PARK BRAKE RELEASE HANDLE  under REMOVAL & INSTALLATION. Did you find and correct a condition? If so, go to step  25 . If not, go to next step.
  21. Replace the park brake pedal assembly (not releasing properly). See PARK BRAKE PEDAL ASSEMBLY  under REMOVAL & INSTALLATION. Did you complete the replacement? After repairs go to step  26 .
  22. Check the adjustment of the park brake. PARK BRAKE ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS. Is the park brake adjusted properly? If so, go to step . If not, go to next step 29 .
  23. Adjust the park brake. See PARK BRAKE ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS. Were you able to attain adjustment of the park brake system? If so, go to step  28 . If not, go to next step.
  24. Remove the rear brake rotors, if they have not yet been removed. See BRAKE ROTORS  under REMOVAL & INSTALLATION. Check the park brake actuators for a seized condition. Replace the park brake actuators as necessary. See PARK BRAKE ACTUATOR  under REMOVAL & INSTALLATION. Did you find and correct a condition? If so, go to next step. If not, go to step  27 .
  25. Adjust the park brake. See PARK BRAKE ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS. Were you able to attain adjustment of the park brake system? If so, go to step  28 . If not, go to step  27 .
  26. Adjust the park brake. See PARK BRAKE ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS. Were you able to attain adjustment of the park brake system? If so, go to step  28 .
  27. Replace the component that is used to adjust the park brake system. See PARK BRAKE EQUALIZER  under REMOVAL & INSTALLATION. Adjust the park brake. See PARK BRAKE ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS. Did you complete the replacement and adjustment? If so, go to next step.
  28. With the transmission still in NEUTRAL, apply the park brake. Attempt to rotate the rear wheels to check the rear brakes for a significant amount of drag. Release the park brake. Rotate the rear wheels to check the rear brakes for a significant reduction of drag. Did the park brake apply and release properly? If so, go to next step.
  29. Install or connect any components that were removed or disconnected during diagnosis. Did you complete the operation? If so, then system is okay. If system is not okay, go to step  4 .
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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.