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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1443 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT DISC BRAKE PADS REPLACEMENT (2500 SERIES)REMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Removal Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2008 GMC Yukon XL, 2008 GMC Yukon, 2008 Chevrolet Tahoe, 2008 Chevrolet Suburban, and 2008 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the fluid level in the brake master cylinder reservoir.
  2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
    6. Fig 1: Compressing Brake Caliper Pistons
    GM370154Courtesy of GENERAL MOTORS CORP.
  6. Compress the brake caliper pistons.
    1. Install 2 large C-clamps over the top of the caliper housing and against the back of the outboard brake pad.
    2. Slowly tighten the C-clamps until the caliper pistons a pushed completely into the caliper bores.
    3. Remove the C-clamps from the caliper.
    7. Fig 2: View Of Brake Caliper Mounting
    GM789166Courtesy of GENERAL MOTORS CORP.
  7. Remove the brake caliper guide pin bolts.
    8. NOTE: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
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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.