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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2175 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR BRAKE CALIPER HARDWARE REPLACEMENT (2500 SERIES)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 does not describe the selected car, but rather 8 other vehicles, including the 2012 GMC Yukon XL, 2012 GMC Yukon, 2012 Chevrolet Tahoe, 2012 Chevrolet Suburban, and 2012 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Caliper Mounting Bolt, Bracket, Boot & Slid Pins
    GM695066Courtesy of GENERAL MOTORS COMPANY
  1. Lubricate the caliper bracket bushings and the slide pins with high temperature silicone brake lubricant.
  2. Install the slide pin boots (4) to the caliper bracket.
  3. Install the slide pins (5) to the caliper bracket (3).
    4. Fig 2: View Of Disc Brake Pads & Brake Caliper Mounting Bracket
    GM369668Courtesy of GENERAL MOTORS COMPANY
  4. Install the anti-rattle clips to the caliper bracket.
  5. Install the brake pads.
  6. Install the caliper to the caliper bracket.
  7. Perform the following procedure before installing the caliper bracket bolts and the brake caliper bolts:
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
    3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
  8. Install the brake caliper bolts. DO NOT tighten.
    9. Fig 3: View Of Rear Caliper Mounting Bolts
    GM913587Courtesy of GENERAL MOTORS COMPANY
  9. Install the brake caliper bracket and caliper as an assembly.
    10. CAUTION:

    Refer to Fastener Caution .

  10. Install the brake caliper bracket bolts and tighten to 200 N.m (148 lb ft).
  11. Tighten the brake caliper bolts to 108 N.m (80 lb ft).
  12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  13. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
  14. Slowly release the brake pedal.
  15. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads.
  16. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. 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.