Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 174 (DISC BRAKE SYSTEM)OVERHAULFRONT CALIPERDISASSEMBLY & REASSEMBLY
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2
Disassembly & Reassembly
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Disassembly & Reassembly
WARNING: This page is about a different car, the 2004 Mazda 3. However, it is still accessible from the selected car via links, so may be relevant.
- Disassemble in the order indicated in the illustration. See Fig 1.
- Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .
Dust Seal Assembly Note
- Assemble a new dust seal to the caliper using Piston Press Rod (49-G033-102) and Socket (49-B033-001) and a press with a press-in force of 187 inch lbs. See Fig 2.
- Verify that there is no gap between the dust seal and caliper body.
Piston Assembly Note
- Press the piston into the dust seal opening as shown in the illustration. See Fig 3, for following steps
- Insert a piece of wood between the caliper body and the piston, and while supporting the piston by hand, blow compressed air through the brake hose installation hole.WARNING: When blowing compressed air into the caliper body, the piston may pop out and cause injury if not supported at the correct point. Securely support the piston friction surface by hand when blowing compressed air.
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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.