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 174 (DISC BRAKE SYSTEM)OVERHAULREAR CALIPERDISASSEMBLY & REASSEMBLY
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6
Disassembly & Reassembly
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Disassembly & Reassembly
WARNING: This page is about a different car, the 2004 Mazda 3. However, it is still accessible from the selected car via links, so may be relevant.
- Disassemble in the order indicated in the illustration. See Fig 1.
- Assemble in the reverse order of disassembly. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Bleed air from system. See BLEEDING BRAKE SYSTEM .
Dust Seal Assembly Note
- While rotating the piston counterclockwise using the Caliper Piston Socket (49-F043-002) and a socket wrench, pull it out to the position shown in the illustration. See Fig 2. As shown in the illustration, assemble a new dust seal on the piston, and rotate the piston clockwise slowly using the caliper piston socket to insert it to the caliper body completely.
- Assemble the dust seal to the caliper body using the Piston Press Rod (49-G033-102) and Socket (49-B026-301) and a press with a press-in force of 187 inch lbs.
- Verify that there is no gap between the dust seal and caliper body.
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.