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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1760 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR DISC BRAKE HARDWARE REPLACEMENT (JL9, JE5)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.
    Fig 1: Identifying Brake Caliper Components
    GM750472Courtesy of GENERAL MOTORS CORP.
  1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots.
  2. Using a suitable tool press the brake caliper pin boots (3) to the brake caliper mounting bracket (4). Do not hammer the boots into the bracket.
  3. Install the brake caliper guide pins (2) to the brake caliper mounting bracket (4).
  4. Install the brake pad retainers to the brake caliper bracket.
  5. Install the brake pads to the brake caliper bracket.
  6. Install the brake caliper to the mounting bracket.
    7. NOTE: If reusing the 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.
  7. Prepare the bolts and the threaded holes for assembly:
    1. Thoroughly clean the residue from the bolt threads by using denatured alcohol or equivalent and allow to dry.
    2. Thoroughly clean the residue from the threaded holes by using denatured alcohol or equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345493 (Canada P/N 10953488), or equivalent to 2/3 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.
    4. Allow the threadlocker to cure approximately 10 minutes before installation.
    5. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins.
    8. CAUTION: Refer to Fastener Caution .
  8. Install the brake caliper bolts (1) and tighten to 60 N.m (44 lb ft).
  9. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
  10. Lower the vehicle.
  11. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling .
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.