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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1262 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR DISC BRAKE PADS REPLACEMENTREMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal 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.
    CAUTION: Refer to Brake Dust Caution .
  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. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
    5. Fig 1: View Of Large C-Clamp Over The Body Of Brake Caliper
    GM808143Courtesy of GENERAL MOTORS CORP.
  5. 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 outboard brake pad.
  6. 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.
  7. Remove the C-clamp from the caliper.
    8. Fig 2: View Of Lower Brake Caliper Guide Pin Bolt
    GM1387173Courtesy of GENERAL MOTORS CORP.
  8. Remove the lower brake caliper guide pin bolt.
    9. NOTE: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
  9. Pivot the brake caliper upward from the caliper bracket and support the caliper out of the way with heavy mechanics wire or equivalent; ensure that there is no tension on the hydraulic brake flexible hose. Do NOT disconnect the hydraulic brake flexible hose from the caliper.
    10. Fig 3: View Of Brake Pads And Brake Caliper Mounting Bracket
    GM1335587Courtesy of GENERAL MOTORS CORP.
  10. Remove the brake pads (1) from the brake caliper mounting bracket (3).
  11. Remove and the brake pad retainers (2) from the brake caliper mounting bracket (3).
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.