Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2092 (ANTILOCK BRAKE SYSTEM - HYBRID (HP2) WITH TRACTION CONTROL SYSTEM & STABILITY CONTROL SYSTEM)REPAIR INSTRUCTIONSBRAKE PIPE MANIFOLD REPLACEMENTINSTALLATION 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 2010 GMC Sierra and 2010 Chevrolet Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: View Of Transfer Tubes & O-ring Seals

Courtesy of GENERAL MOTORS CORP.

Assemble the 5 transfer tubes (1) to 5 new upper transfer tube O-ring seals (2).
Install the 5 new lower transfer tube O-ring seals (3).
Lubricate the new O-ring seals with GM approved brake fluid from a clean, sealed brake fluid container.
Install the transfer tube assemblies to the brake modulator valve assembly.

Fig 2: Identifying Supply & Return Transfer Tube O-Ring Seals

Courtesy of GENERAL MOTORS CORP.

Assemble 4 new O-ring seals to the supply and return transfer tubes (1).
Lubricate the new O-ring seals with GM approved brake fluid from a clean, sealed brake fluid container.
Install the supply and return transfer tube assemblies to the brake modulator valve assembly.

Fig 3: View Of Brake Pipe Manifold

Courtesy of GENERAL MOTORS CORP.

Install the brake pipe manifold (1).

Fig 4: Identifying Brake Pipe Manifold Bolts

Courtesy of GENERAL MOTORS CORP.

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.