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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1352 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE CALIPER REPLACEMENT (AWD)INSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the brake caliper guide pins, seals and brake pad springs for damage and/or corrosion. Refer to Front Disc Brake Mounting and Hardware Inspection .
    2. Fig 1: View of Caliper and Rotor
    GM1969924Courtesy of GENERAL MOTORS CORP.
  2. Install the brake caliper (1).
    3. Fig 2: Identifying Brake Hose and Bolt
    GM1969922Courtesy of GENERAL MOTORS CORP.
  3. Assemble the brake hose fitting bolt (1) and 2 new brake hose fitting gaskets (2) to the brake hose (3).
    4. NOTE: Refer to Fastener Notice .
  4. Install the brake hose assembly to the caliper.

    Tighten:  Tighten the bolt to 49 N.m (36 lb ft).

    5. IMPORTANT: If reusing the brake caliper guide pin bolts, the threads of the brake caliper guide pin bolts and the threads of the guide pins must be free of residue and debris prior to application of threadlocker in order to ensure proper adhesion and fastener retention.
  5. If reusing the caliper pin bolts, prepare the bolts and the guide pins for assembly:
    • Thoroughly clean the residue from the guide pin bolt threads by using denatured alcohol or equivalent and allow to dry.
    • Thoroughly clean the residue from the guide pin threads by using denatured alcohol or equivalent and allow to dry.
  6. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488), or equivalent to 2/3 of the threaded length of the brake caliper guide pin bolts. Ensure there are no gaps in the threadlocker along the length of the filled area of the bolts.
  7. Allow the threadlocker to cure approximately 10 minutes before installation.
    8. Fig 3: View of Brake Caliper, Guide and Bolts
    GM1969908Courtesy of GENERAL MOTORS CORP.
  8. Using a backup wrench on the brake caliper guide pin, install the brake caliper guide pin bolts (1).

    Tighten: 

    • For JE5, tighten the bolts to 27N.m (20lb ft).
    • For J55, tighten the bolts to 65 N.m (48 lb ft).

  9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .

    Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

  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 11 and 12 until a firm brake pedal apply 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 .
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.