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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 771 (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 2011 GMC Yukon XL, 2011 GMC Yukon, 2011 Chevrolet Tahoe, 2011 Chevrolet Suburban, and 2011 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE:

    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  Wheel Hub Resurfacing Kit to clean all rust and contaminants from the mating surface of the hub flange.
  2. Use the J-41013  Rotor Resurfacing Kit 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.
  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: 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. Fig 2: Rear Brake Caliper Mounting Bracket Bolts (15 Series w/NYS)
    GM789156Courtesy of GENERAL MOTORS CORP.
  6. Install the caliper and caliper bracket as an assembly.
  7. 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.
    8. CAUTION:

    Refer to Fastener Caution .

  8. Install the brake caliper bracket bolts and tighten to 200 N.m (148 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 13-14 until a firm pedal is obtained. This will properly seat the caliper pistons and pads.
  13. Fill the master cylinder reservoir to the proper level with clean brake fluid, if necessary. Refer to Master Cylinder Reservoir Filling .
  14. If the brake rotor was refinished or replaced, burnish the brake 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.