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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1760 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR BRAKE CALIPER REPLACEMENT (JE5, 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 caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Disc Brake Hardware Replacement (JL9, JE5)  or Rear Disc Brake Hardware Replacement (J56) .
    2. Fig 1: View Of Caliper Assembly & Retainers
    GM63989Courtesy of GENERAL MOTORS CORP.
  2. Install the brake caliper to the brake caliper bracket.
    3. NOTE: If reusing the brake caliper pin bolts the threads of the caliper pin bolts 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.
  3. Prepare the bolts and the threaded holes 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.
  4. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488), or equivalent to two-thirds of the threaded length of the lower caliper bracket bolts. Ensure that there are no gaps in the threadlocker along the length of the filled area of the bolts.
  5. Allow the threadlocker to cure approximately ten minutes before installation.
  6. Apply a thin coat of high temperature silicone brake lubricant to the brake caliper pin bolts.
    7. CAUTION: Refer to Fastener Caution .
  7. Install the brake caliper pin bolts and tighten to 60 N.m (44 lb ft).
    8. Fig 2: View Of Brake Caliper & Brake Hose
    GM63948Courtesy of GENERAL MOTORS CORP.
  8. Remove the plug from the brake caliper opening and the brake hose.
    9. NOTE: Install NEW copper brake hose gaskets.
  9. Assemble the NEW copper brake hose gaskets, and the brake caliper bolt to the brake hose.
  10. Install the brake hose and the brake caliper bolt to the brake caliper and tighten to 50 N.m (37 lb ft).
  11. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
  12. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  13. Slowly release the brake pedal.
  14. Wait 15 seconds, then repeat steps 12 and 13 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads.
  15. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  16. Lower the vehicle.
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.