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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1434 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE ROTOR REPLACEMENT (AWD)INSTALLATION 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 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.
    IMPORTANT: The brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.
  1. Using the J 42450-A  , thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. See Special Tools .
  2. Using the J 41013  , thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. See Special Tools .
  3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
    4. Fig 1: View of Brake Rotor and Flange
    GM1969914Courtesy of GENERAL MOTORS CORP.
  4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange.
    5. NOTE: Refer to Fastener Notice .
  5. Install the brake rotor screw (1).

    Tighten:  Tighten the screw to 10 N.m (89 lb in).

  6. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement .
  7. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction .
    8. IMPORTANT: If reusing the caliper bracket bolts the threads of the caliper bracket bolts and the threads of the knuckle mounting holes must be free of residue and debris prior to application of threadlocker in order to ensure proper adhesion and fastener retention.
  8. Prepare the bolts and the threaded holes for assembly:
    • Thoroughly clean the residue from the bolt threads by using denatured alcohol or equivalent and allow to dry.
    • Thoroughly clean the residue from the threaded holes by using denatured alcohol or equivalent and allow to dry.
    • Apply threadlocker GM P/N 12345493 (Canada P/N 10953488), or equivalent to 2/3 of the threaded length of the lower caliper bracket bolts. Ensure there are no gaps in the threadlocker along the length of the filled area of the bolts.
    • Allow the threadlocker to cure approximately 10 minutes before installation.
    9. Fig 2: View of Caliper and Bracket Assembly
    GM1969913Courtesy of GENERAL MOTORS CORP.
  9. Install the brake caliper and bracket assembly to the knuckle.
  10. Install the brake caliper bracket bolts (1).

    Tighten:  Tighten the bolts to 225 N.m (166 lb ft).

  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  12. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing .
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.