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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1240 (HYDRAULIC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE HOSE REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Malibu Classic. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Brake Caliper, Brake Hose Banjo Bolts & Brake Hose Gaskets
    GM451132Courtesy of GENERAL MOTORS CORP.
  1. Remove the caps or plugs from the opening in the brake caliper and the brake hose.
    2. IMPORTANT: Install NEW copper brake hose gaskets.
  2. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3).
    3. NOTE: Refer to Fastener Notice .
  3. Install the brake hose-to-brake caliper bolt to the brake caliper.

    Tighten:  Tighten the bolt to 50 N.m (37 lb ft).

    4. Fig 2: View Of Front Brake Hose And Brake Pipe Fitting
    GM1219618Courtesy of GENERAL MOTORS CORP.
  4. Install the brake hose to the strut with the brake hose nut (4).

    Tighten:  Tighten the nut to 14 N.m (124 lb in).

  5. Remove the caps or plugs from the brake pipe fitting end and the brake hose end.
  6. Install the brake hose to the brake hose body bracket.
  7. Install the brake hose retainer (2) over the anti-rotation tabs of the brake hose (3).
  8. Connect the brake pipe fitting (1) to the brake hose (3).
  9. Use a backup wrench on the brake hose (3).
  10. Tighten the brake pipe fitting.

    Tighten:  Tighten the brake pipe fitting to 20 N.m (15 lb ft).

  11. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition.
  12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure)  or Hydraulic Brake System Bleeding (Manual) .
  13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  14. Lower the vehicle.
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.