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.

SYS.OK|MANUAL.DB● LIVE

HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1760 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE CALIPER OVERHAUL (J56)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 is about a different car, the 2009 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Exploded View Of Caliper

Courtesy of GENERAL MOTORS CORP.

Install the new piston dust boot seals (3) over the pistons (4). Make sure the dust boot seal is properly seated on the piston, in the dust boot seal groove.
Lubricate the new piston seals (5) with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
Install the lubricated, new piston seals (5) into the brake caliper bore seal grooves. Make sure the seals are not twisted.
Apply a thin coat of Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container, onto the caliper piston bores and the outer surface of the caliper pistons.
Install the piston and dust boot assemblies into the correct caliper bores. Press the pistons and dust boot seals all the way in by hand.
Place a clean old brake pad or the fabricated 127 mm (5 in) long block of wood over 2 adjoining piston bores and apply light pressure with non-marring C-clamp. This will ensure the dust boots and pistons are fully seated into the caliper.
Repeat step 6 for the opposite pistons.

CAUTION: Refer to Fastener Caution .

Install the brake caliper bleeder valves (2).
Tighten: Tighten the valves to 14 N.m (124 lb in).
Install the brake caliper bleeder valve caps (1).
Install the caliper to the vehicle. Refer to Front Brake Caliper Replacement (JE5) or Front Brake Caliper Replacement (JL9) or Front Brake Caliper Replacement (J56) .

RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready Tools Free Quote Check Quote Shield Pro

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.