Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1436 (HYDRAULIC BRAKE SYSTEM)REPAIR INSTRUCTIONSMASTER CYLINDER 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 Cadillac CTS. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Removing/Installing Master Cylinder Nuts

Courtesy of GENERAL MOTORS CORP.

If installing a new master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding .
Install the master cylinder to the vacuum brake booster.

NOTE: Refer to Fastener Notice .

Install the master cylinder nuts (1).
Tighten: Tighten the nuts to 25 N.m (18 lb ft).

Fig 2: Removing/Installing Master Cylinder Secondary Brake Pipe Fitting

Courtesy of GENERAL MOTORS CORP.

Install the master cylinder secondary brake pipe fitting (1).
Tighten: Tighten the fitting to 32 N.m (24 lb ft).

Fig 3: Identifying Master Cylinder Primary Brake Pipe Fitting

Courtesy of GENERAL MOTORS CORP.

Install the master cylinder primary brake pipe fitting (1).
Tighten: Tighten the fitting to 32 N.m (24 lb ft).
Connect the master cylinder fluid level sensor electrical connector.
Rotate the air inlet panel and position the support bracket to the master cylinder mounting stud.
Install the air inlet panel support bracket push nut.
Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .

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.