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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 320 (DISC BRAKE SYSTEM)REPAIR INSTRUCTIONSREAR BRAKE ROTOR 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.
    IMPORTANT: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation.
  1. Use the J 42450-A  to clean all rust and contaminants from the mating surface of the hub flange. See Special Tools .
  2. Use the J 41013  to clean all rust and contaminants from the inside diameter of the hat section of the brake rotor to prevent any foreign material from getting between the brake rotor and the hub flange. See Special Tools .
  3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
  4. Align the rotor to its original position on the hub, if applicable.
    5. Fig 1: View Of Rear Brake Rotor
    GM686151Courtesy of GENERAL MOTORS CORP.
  5. Install the rotor by slowly turning the rotor while pushing the rotor towards the axle.
  6. If the rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement .
  7. If the rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction .
    8. Fig 2: Rear Brake Caliper Mounting Bracket Bolts (15 Series w/NYS)
    GM789156Courtesy of GENERAL MOTORS CORP.
  8. Install the caliper and caliper bracket as an assembly.
  9. Perform the following procedure before installing the brake caliper bracket bolts:
    1. Remove all traces of the original adhesive patch.
    2. Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry.
    3. Apply threadlocker GM P/N 12345493 (Canadian P/N 10953488) to the threads of the bolts.
    10. NOTE: Refer to Fastener Notice .
  10. Install the brake caliper bracket bolts.

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

  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 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads.
  16. 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.