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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 (JL9)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation 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 brake caliper guide pin bolts. If damaged or corroded, replace the brake caliper guide bolts.
  2. Inspect the brake caliper guide pins. If damaged or corroded, replace the brake caliper guide pin. Do not attempt to clean away any corrosion. Refer to Front Disc Brake Hardware Replacement (JE5)  or Front Disc Brake Hardware Replacement (JL9)  or Front Disc Brake Hardware Replacement (J56) .
  3. Inspect the brake caliper guide pin boots for cuts, tears, or deterioration. If damaged, replace the brake caliper guide pin boots. Refer to Front Disc Brake Hardware Replacement (JE5)  or Front Disc Brake Hardware Replacement (JL9)  or Front Disc Brake Hardware Replacement (J56) .
  4. Inspect the brake caliper piston boot for deterioration. Replace if damaged. Refer to Front Brake Caliper Overhaul (JE5)  or Front Brake Caliper Overhaul (JL9)  or Front Brake Caliper Overhaul (J56) .
    5. Fig 1: Compressing Caliper Piston
    GM728143Courtesy of GENERAL MOTORS CORP.
  5. Install a large C-clamp (1) over the body of the brake caliper (3), with the C-clamp ends against the rear of the caliper body and against an old inboard brake pad (2) or a wood block installed against the caliper pistons.
  6. Tighten the C-clamp (1) evenly until the caliper pistons are compressed completely into the caliper bores.
  7. Remove the C-clamp and the old brake pad or wood block from the caliper.
    8. Fig 2: Locating Brake Pads
    GM756426Courtesy of GENERAL MOTORS CORP.
  8. Install the brake pad retainers to the caliper bracket.
  9. Install the brake pads (1) to the caliper bracket.
  10. Pivot the brake caliper (1) downward, over the brake pads and into the caliper bracket.
    11. NOTE: If reusing the lower caliper pin bolt, the threads of the lower caliper pin bolt and the threads of the caliper bracket mounting holes must be free of residue and debris prior to application of threadlocker in order to ensure proper adhesion and fastener retention.
  11. If reusing the caliper pin bolts, prepare the bolt and the threaded hole for assembly:
    • Thoroughly clean the residue from the bolt threads by using denatured alcohol or equivalent and allow to dry.
    • Thoroughly clean the residue from the threaded holes by using denatured alcohol or equivalent and allow to dry.
  12. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488), or equivalent to 2/3 of the threaded length of the lower caliper pin bolt. Ensure that there are no gaps in the threadlocker along the length of the filled area of the bolt.
  13. Allow the threadlocker to cure approximately 10 minutes before installation.
  14. Apply a thin coat of high temperature silicone lube to the front brake caliper guide pin.
    15. CAUTION: Refer to Fastener Caution .
  15. Install the lower brake caliper pin bolt.

    Tighten:  Hold the lower brake caliper guide pin with a wrench and tighten the lower brake caliper pin bolt to 63 N.m (46 lb ft).

  16. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  17. Lower the vehicle.
  18. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  19. Slowly release the brake pedal.
  20. Wait 15 seconds, then repeat steps 18 and 19 until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  21. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling .
  22. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing .
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.