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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 932 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE 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 does not describe the selected car, but rather 6 other vehicles, including the 2007 GMC Savana Special, 2007 GMC Savana Camper Special, 2007 GMC Savana, 2007 Chevrolet RV Cutaway, and 2007 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Brake Caliper Mounting
    GM789166Courtesy of GENERAL MOTORS CORP.
  1. Install the brake caliper to the brake caliper mounting bracket.
  2. Perform the following procedure before installing the caliper mounting bolts.
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with brake parts cleaner or the equivalent and allow to dry.
    3. Apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
    3. NOTE: Refer to Fastener Notice .
  3. Install the 2 brake caliper mounting bolts.

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

  4. Remove the rubber cap or plug from the exposed brake hose fitting end.
    5. IMPORTANT: Install 2 new copper brake hose gaskets.
  5. Assemble the 2 new copper brake hose gaskets and the brake hose to caliper bolt to the brake hose.
    6. Fig 2: View Of Brake Hose To Caliper Bolt
    GM367082Courtesy of GENERAL MOTORS CORP.
  6. Install the brake hose to caliper bolt to the brake caliper.

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

  7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
  8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  9. Lower the vehicle.
  10. Fill the master cylinder reservoir to the proper level with clean brake fluid. Refer to Master Cylinder Reservoir Filling .
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.