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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1525 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT DISC BRAKE HARDWARE REPLACEMENT (2500 SERIES)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 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.
    Fig 1: View Of Caliper, Pin, Boots & Caliper Mounting Bracket
    GM344219Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the caliper bushings, bolts and seals with high temperature silicone brake lubricant.
  2. Install the caliper guide pin boots (4) to the caliper bracket (3).
    3. Fig 2: View Of Brake Caliper Mounting
    GM789166Courtesy of GENERAL MOTORS CORP.
  3. Install the brake caliper to the caliper bracket.
    4. NOTE: Refer to Fastener Notice .
  4. Install the brake caliper guide pin bolts.

    Tighten:  Tighten the bolts to 108 N.m (80 lb ft).

  5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  6. Lower the vehicle.
  7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  8. Slowly release the brake pedal.
  9. Wait 15 seconds, then repeat steps 7-8 until a firm brake pedal is obtained, to properly seat the brake caliper pistons and brake pads.
  10. Slowly apply pressure to the brake pedal until a firm brake pedal is achieved.
  11. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling (JD9, JH6) or Master Cylinder Reservoir Filling (Two-mode Hybrid) .
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.