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 1525 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE CALIPER OVERHAUL (2500 SERIES)ASSEMBLY PROCEDURE

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Assembly Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Assembly Procedure

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2008 GMC Yukon XL, 2008 GMC Yukon, 2008 Chevrolet Tahoe, 2008 Chevrolet Suburban, and 2008 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: When applying the clean brake fluid to the piston bores, piston seals and pistons, only apply the brake fluid to one bore at a time. This is done to ensure that the brake caliper, seals and pistons DO NOT become contaminated with dirt or other foreign material.

Apply a small amount of clean DOT-3 brake fluid to the piston, piston seal, and piston bore.

Fig 1: View Of Brake Caliper Piston Seal

Courtesy of GENERAL MOTORS CORP.

Install the square-cut piston seal in the brake caliper bore groove.
Ensure that the square-cut piston seal is not twisted.

Fig 2: View Of Piston Dust Seal

Courtesy of GENERAL MOTORS CORP.

Install the boot over the end of the piston so that the fold will face toward the brake caliper housing piston bore opening.

Fig 3: Installing Piston To Brake Caliper

Courtesy of GENERAL MOTORS CORP.

RENDER: 1.0x

NO RELATED

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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.