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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 REPLACEMENT (J56)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal 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.
  1. Inspect the fluid level in the brake master cylinder reservoir.
  2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
  3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
    6. NOTE: Use ONLY a plastic flat-bladed trim tool and/or another suitable soft tool when compressing the caliper pistons into the caliper piston bores. Never use any type of metal tool between the brake rotor and brake pads to compress the caliper pistons into the bores.
  6. Carefully insert a plastic flat-bladed trim tool between the rotor and inboard brake pad.
  7. Carefully apply pressure to the inboard brake pad until both caliper inner pistons are compressed into the caliper piston bores.
  8. Carefully insert a plastic flat-bladed trim tool between the rotor and outboard brake pad.
  9. Carefully apply pressure to the outboard brake pad until both caliper outer pistons are compressed into the bores.
    10. Fig 1: Locating Brake Hose-To-Caliper Bolt
    GM1350454Courtesy of GENERAL MOTORS CORP.
  10. Remove the brake hose to caliper bolt attaching the brake hose to the brake caliper.
  11. Remove the brake hose from the brake caliper.
  12. Remove and discard the two copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.
  13. Plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
    14. Fig 2: Locating Brake Caliper-To-Knuckle Mounting Bolts
    GM1349659Courtesy of GENERAL MOTORS CORP.
  14. Remove the brake caliper bolts (1).
  15. Remove the brake caliper from the wheel knuckle.
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.