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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 833 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSBRAKE CALIPER REPLACEMENTREMOVAL 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 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Inspecting Caliper For Looseness
    GM171943Courtesy of GENERAL MOTORS CORP.
  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 .
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub.
  7. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad.
  8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor.
  9. Remove the C-clamp from the caliper.
    10. Fig 2: Removing/Installing Copper Brake Hose Gaskets
    GM925904Courtesy of GENERAL MOTORS CORP.
  10. Remove the brake hose-to-caliper bolt from the brake caliper.
  11. Remove the brake hose from the brake caliper.
  12. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
    14. Fig 3: Removing/Installing Brake Caliper Guide Pins
    GM933137Courtesy of GENERAL MOTORS CORP.
  14. Remove the brake caliper guide pin bolts.
  15. Remove the brake caliper from the caliper bracket.
  16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:
    • Restricted caliper guide pin movement
    • Looseness in the brake caliper mounting bracket
    • Seized or binding caliper guide pins
    • Split or torn boots
  17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.
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.