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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1262 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE CALIPER 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 Guide Pin Bolts
    GM891307Courtesy of GENERAL MOTORS CORP.
  1. Install the brake caliper to the brake caliper bracket.
    2. NOTE: Refer to Fastener Notice .
  2. Install the brake caliper guide pin bolts (2).

    Tighten:  Tighten the bolts to 35 N.m (26 lb ft).

    3. Fig 2: View Of Front Brake Hose
    GM890982Courtesy of GENERAL MOTORS CORP.
  3. Remove the caps or plugs from the brake caliper opening and the brake hose.
    4. IMPORTANT: Do not reuse the copper brake hose gaskets.
  4. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3).
  5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper.

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

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