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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)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, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Using a C-clamp installed to the center of the outer brake pad and the back of the caliper, slowly compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket.
    5. CAUTION: 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.
  5. To loosen the brake caliper pin bolts, hold the brake caliper guide pin with a wrench.
  6. Remove the brake caliper bolts.
  7. Remove the brake caliper from the mounting bracket.
  8. Remove the brake pads from the disc brake caliper bracket.
    9. Fig 1: View Of Brake Pads & Caliper Bracket - Rear
    GM695055Courtesy of GENERAL MOTORS CORP.
  9. Remove the brake pad retainers from the disc brake caliper bracket.
    10. Fig 2: Identifying Brake Caliper Components
    GM750472Courtesy of GENERAL MOTORS CORP.
  10. Remove the brake caliper guide pins (2) from the brake caliper mounting bracket (4).
  11. Remove the caliper pin boots (3) from the brake caliper mounting bracket (4).
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.