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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 PADS REPLACEMENT (J56)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: View Of Brake Pads & Mounting Pin
    GM1349658Courtesy of GENERAL MOTORS CORP.
  1. Inspect the brake caliper guide pins. If damaged, or corroded replace the guide pin. Do not attempt to clean away any corrosion.
  2. Inspect the brake caliper piston boot for damage and/or deterioration, replace if damaged or deteriorated. Refer to Front Brake Caliper Overhaul (JE5)  or Front Brake Caliper Overhaul (JL9)  or Front Brake Caliper Overhaul (J56) .
  3. Install the brake pads (1) to the caliper.
  4. Install the upper caliper guide pin (2) through the caliper, inner and outer brake pads.
  5. Using a hammer and punch seat the upper guide pin to the outer caliper half. Ensure that the caliper guide pin is seated into the outer caliper pin seat.
    6. Fig 2: Identifying Lower Caliper Guide Pin & Brake Pad Retainer
    GM1349657Courtesy of GENERAL MOTORS CORP.
  6. Install the brake pad retainer (1) under the upper caliper pin assembly.
  7. Rotate brake pad retainer down.
  8. Carefully apply pressure downward on the lower end of the brake pad retainer.
  9. Carefully install the lower caliper guide pin (2) through the caliper, inner and outer brake pads.
  10. Using a hammer and punch seat the lower guide pin to the outer caliper half. Ensure that the caliper guide pin is seated into the outer caliper pin seat. Ensure that the brake pad retainer is centered retaining both brake pads.
  11. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  12. Lower the vehicle.
  13. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  14. Slowly release the brake pedal.
  15. Wait 15 seconds, then repeat steps 13 and 14 until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads.
  16. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling .
  17. 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.