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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1760 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT BRAKE CALIPER OVERHAUL (JE5)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: View Of Brake Caliper Bleeder Valve
    GM1201165Courtesy of GENERAL MOTORS CORP.
  1. Install the valve stem seal (2) over the threaded end of the bleeder valve (1).
    2. CAUTION: Refer to Fastener Caution .
  2. Install the brake caliper bleeder valve (1).

    Tighten:Ā  Tighten the bleeder valve to 14 N.m (124 lb in).

  3. Install the brake caliper bleeder valve cap.
    4. Fig 2: View Of Piston Seals - Front
    GM806399Courtesy of GENERAL MOTORS CORP.
  4. Lubricate the new piston seals (1) with Delco Supreme 11Ā®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
  5. Install lubricated piston seals into the brake caliper bore seal grooves.
  6. Make sure the seals are not twisted.
    7. Fig 3: View Of Piston & Dust Boot
    GM1200888Courtesy of GENERAL MOTORS CORP.
  7. Install the piston dust boot (2) over the end of the piston (3) so that the fold will face toward the brake caliper housing piston bore opening.
  8. Seat the caliper dust boot into the brake caliper bore groove (1) and slide the piston into the brake caliper bore.
    9. Fig 4: Pushing Piston To Bottom Of Brake Caliper Bore
    GM1200891Courtesy of GENERAL MOTORS CORP.
  9. Using your fingers, carefully push the piston to the bottom of the brake caliper bore.
  10. Ensure the caliper dust boot is properly seated into the piston groove and into the groove in the brake caliper bore.
  11. Repeat steps 5-10 for the remaining piston.
  12. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement (JE5)Ā  or Front Brake Caliper Replacement (JL9)Ā  or Front Brake Caliper Replacement (J56)Ā .
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:

  • ā€¢ You smell fuel, burning insulation, or see smoke.
  • ā€¢ Brakes feel soft, pull hard to one side, or make grinding noises.
  • ā€¢ The engine overheats, stalls repeatedly, or misfires under load.
  • ā€¢ You are missing required tools, torque specs, or safe lifting equipment.
  • ā€¢ You are not confident in the next step or safety outcome.