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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 579 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE PADS REPLACEMENT - FRONTINSTALLATION 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 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and the boots. Refer to Disc Brake Hardware Replacement - Front .
    2. Fig 1: Compressing Caliper Piston
    GM728143Courtesy of GENERAL MOTORS CORP.
  2. Install large C-clamp (1) over the body of the brake caliper (3) with the C-clamp ends against the rear of the caliper body and against an old inboard brake pad (2) or a wood block installed against the caliper pistons.
  3. Tighten the C-clamp (1) evenly until the caliper pistons are compressed completely into the caliper bores.
  4. Remove the C-clamp and the old brake pad or wood block from the caliper.
    5. Fig 2: View Of Brake Caliper & Bracket
    GM171937Courtesy of GENERAL MOTORS CORP.
  5. Install the brake pad retainers to the caliper bracket.
  6. Install the brake pads to the caliper bracket. The brake pad wear sensor, mounted on the inboard brake pad, must be positioned so that it is in the trailing position during forward rotation of the brake rotor.
  7. Pivot the brake caliper upward, over the brake pads and into the caliper bracket.
    8. NOTE: Refer to Fastener Notice in Cautions and Notices.
  8. Install the upper brake caliper guide pin bolt.

    Tighten:  Tighten the brake caliper guide pin bolt to 31 N.m (23 lb ft).

  9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  10. Lower the vehicle.
  11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  12. Slowly release the brake pedal.
  13. Wait 15 seconds, then repeat steps 11-12 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads.
  14. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
  15. Burnish the pads and rotors. Refer to Burnishing Pads and Rotors .
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.