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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 441 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE CALIPER REPLACEMENT - FRONTREMOVAL 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 is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. 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 in General Information.
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  6. Compress the brake caliper pistons.
    • Install a large C-clamp over the top of the caliper housing and against the back of the outboard pad.
    • Slowly tighten the C-clamp until the pistons are pushed completely into the caliper bores.
    • Remove the C-clamp from the caliper.
    7. Fig 1: Compressing Brake Caliper Pistons
    GM370154Courtesy of GENERAL MOTORS CORP.
  7. Clean all dirt and foreign material from the brake hose end.
    8. IMPORTANT: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination.
  8. Remove the brake hose to caliper bolt from the brake caliper.
  9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper housing or the brake hose end.
  10. Remove the brake hose from the caliper.
    11. Fig 2: View Of Brake Hose To Caliper Bolt
    GM367082Courtesy of GENERAL MOTORS CORP.
  11. Remove the 2 brake caliper mounting bolts.
    12. Fig 3: View Of Brake Caliper Mounting
    GM789166Courtesy of GENERAL MOTORS CORP.
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.