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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 735 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSDISC BRAKE HARDWARE REPLACEMENT - FRONT (25/3500 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 is about a different car, the 2006 GMC Sierra, 2006 GMC Cab & Chassis Sierra, 2006 Chevrolet Silverado, and 2006 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
  2. Install the caliper pin boots (4) to the caliper bracket (3).
    Fig 1: View Of Caliper, Pin, Boots & Caliper Mounting Bracket
    GM344219Courtesy of GENERAL MOTORS CORP.
  3. Install the brake pad retainers to the caliper bracket.
    Fig 2: View Of Disc Brake Pads & Brake Caliper Mounting Bracket
    GM369668Courtesy of GENERAL MOTORS CORP.
  4. Install the brake pads.
    5. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  5. Install the caliper to the caliper bracket.
  6. Install the brake caliper bolts.
    Fig 3: View Of Brake Caliper Mounting
    GM789166Courtesy of GENERAL MOTORS CORP.

    Tighten:  Tighten the bolts to 108 N.m (80 lb ft).

  7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  8. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance.
  9. Slowly release the brake pedal.
  10. Wait 15 seconds, then repeat steps 6-7 until a firm brake pedal is obtained. This will properly seat the caliper pistons and pads.
  11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling in Hydraulic Brakes.
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.