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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1760 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSFRONT DISC BRAKE PADS REPLACEMENT (JE5)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 suitably 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. Fig 1: Identifying Large C-Clamp Over The Body Of The Brake Caliper
    GM808146Courtesy of GENERAL MOTORS CORP.
  6. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outboard brake pad.
  7. Tighten the C-clamp evenly until the caliper pistons are compressed into the caliper bores enough to allow the caliper to slide past the brake rotor.
  8. Remove the C-clamp from the caliper.
    9. Fig 2: View Of Brake Caliper Body
    GM756418Courtesy of GENERAL MOTORS CORP.
  9. To loosen the brake caliper lower pin bolt, hold the brake caliper guide pin with a wrench.
  10. Remove the brake caliper pin bolt.
    11. NOTE: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
  11. Pivot the brake caliper body (1) upward and secure the caliper out of the way with heavy mechanic's wire or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Do NOT disconnect the hydraulic brake flexible hose from the caliper.
    12. Fig 3: Locating Brake Pads
    GM756426Courtesy of GENERAL MOTORS CORP.
  12. Remove the brake pads (1) from the caliper bracket.
  13. Remove and inspect the brake pad retainers from the caliper bracket.
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.