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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 320 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR BRAKE CALIPER BRACKET REPLACEMENT (2500 SERIES)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2008 GMC Yukon XL, 2008 GMC Yukon, 2008 Chevrolet Tahoe, 2008 Chevrolet Suburban, and 2008 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Disc Brake Pads & Brake Caliper Mounting Bracket
    GM369668Courtesy of GENERAL MOTORS CORP.
  1. Install the retaining springs to the caliper bracket.
  2. Install the brake pads.
    3. Fig 2: View Of Rear Caliper Mounting Bolts
    GM913587Courtesy of GENERAL MOTORS CORP.
  3. Install the caliper to the caliper bracket.
  4. Install the brake caliper guide pin bolts to the caliper bracket. DO NOT tighten.
    5. Fig 3: Brake Caliper Bracket Mounting & Bolts
    GM794150Courtesy of GENERAL MOTORS CORP.
  5. Install the caliper and caliper bracket (1) as an assembly.
  6. Perform the following procedure before installing the caliper bracket bolts.
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolt with denatured alcohol or equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolt.
    7. NOTE: Refer to Fastener Notice .
  7. Install the brake caliper bracket mounting bolts (2).

    Tighten:  Tighten the bolts to 200 N.m (148 lb ft).

  8. Tighten the brake caliper guide pin bolts.

    Tighten:  Tighten the bolts to 108 N.m (80 lb ft).

  9. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
  11. Slowly release the brake pedal.
  12. Wait 15 seconds, then repeat steps 10-11 until a firm pedal is obtained to properly seat the brake caliper pistons and brake pads.
  13. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling (JD9, JH6) or Master Cylinder Reservoir Filling (Two-mode Hybrid) .
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.