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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 833 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE CALIPER REPLACEMENTINSTALLATION 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 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Brake Caliper Guide Pins
    GM933137Courtesy of GENERAL MOTORS CORP.
  1. Apply a light, thin coat of high temperature silicone brake lubricant to the caliper guide pins.
  2. Install the guide pins to the brake caliper bracket.
  3. Install the brake caliper to the brake caliper bracket.
    4. NOTE: Refer to Fastener Notice .
  4. Install the brake caliper guide pin bolts.

    Tighten:  Tighten the bolts to 44 N.m (32 lb ft).

    5. Fig 2: Removing/Installing Copper Brake Hose Gaskets
    GM925904Courtesy of GENERAL MOTORS CORP.
  5. Remove the caps or plugs from the brake caliper opening and the brake hose.
    6. IMPORTANT: Do not reuse the copper brake hose gaskets.
  6. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose.
  7. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper.

    Tighten:  Tighten the bolt to 44 N.m (32 lb ft).

  8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure) or Hydraulic Brake System Bleeding (Manual) .
  9. Remove the wheel nuts retaining the brake rotor to the wheel hub.
  10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  11. Lower the vehicle.
  12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  13. Slowly release the brake pedal.
  14. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
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.