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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 753 (REAR DRIVE AXLE)REPAIR INSTRUCTIONSDIFFERENTIAL REPLACEMENT (AUTOMATIC TRANSMISSION)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Installation Procedure
WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
    Fig 1: Transmission Case & Differential Plate Seal Flush
    GM194916Courtesy of GENERAL MOTORS CORP.
  1. Install the differential plate to the transmission, use care not to damage the transmission output seal in the rear of the plate.
  2. Position the square-lip differential plate seal flush with the transmission case.
    3. Fig 2: Differential, Transmission Bolts & Nuts
    GM71505Courtesy of GENERAL MOTORS CORP.
  3. SLOWLY slide the differential to the transmission.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the differential to transmission bolts and nuts.

    Tighten:  Tighten the differential to transmission bolts and nuts to 50 N.m (37 lb ft).

    5. Fig 3: J 42055, Driveline Support Assembly And The Differential
    GM196196Courtesy of GENERAL MOTORS CORP.
  5. Position the chainfall, or equivalent lifting device, in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly.
    6. IMPORTANT: The aid of an assistant will be necessary for the following steps until the driveline is installed into the vehicle.
  6. Using the lifting device, raise the driveline off the workbench and position the driveline with the J 42055  onto a transmission jack.
  7. Connect the J 42055  to the transmission jack.
    8. Fig 4: Propeller Input Shaft
    GM71466Courtesy of GENERAL MOTORS CORP.
  8. Remove the lifting device from the driveline.
  9. Position the driveline under the vehicle.
  10. Begin to raise the driveline at the approximate angle used during removal.
  11. Position the wiring harness along the driveline support assembly and LOOSELY install the harness into the harness retaining slots.
  12. Have an assistant guide the front of the driveline so the propeller input shaft is just to the rear of the engine flywheel housing, then raise the driveline to the PROPER HEIGHT and the PROPER ANGLE to install to the engine.
    13. IMPORTANT: Use care not to use too much force to install the propeller input shaft into the propeller shaft hub. The propeller input shaft front bearing positioning system is designed to withstand an insertion force not greater than 582 N (130 lb).
  13. Have an assistant begin to insert the propeller input shaft into the propeller shaft hub while maintaining the proper angle of the driveline, if necessary use a screwdriver to rotate the shaft slightly to bring the splines into alignment.
    14. Fig 5: Supporting Transmission Using Jackstand
    GM196198Courtesy of GENERAL MOTORS CORP.
  14. SLOWLY seat the driveline to the engine flywheel housing while maintaining the proper angle of the driveline.
    15. Fig 6: Wiring Harness Bracket
    GM71406Courtesy of GENERAL MOTORS CORP.
  15. Reposition the wiring harness bracket from near the driveline tunnel wall to align with the appropriate driveline support assembly bolt hole.
    16. Fig 7: Removing/Installing Driveline Support Assembly To Engine Flywheel Housing Bolts
    GM196199Courtesy of GENERAL MOTORS CORP.
  16. Install the driveline support assembly to engine flywheel housing bolts.

    Tighten:  Tighten the driveline support assembly to engine flywheel housing bolts to 50 N.m (37 lb ft).

  17. Install the wiring harness to the wiring harness retainer along the top of the transmission.
  18. SLOWLY raise the driveline to approximately 50 mm (2 in) BELOW the final installed height.
    19. Fig 8: Locating Cooler Fittings
    GM71418Courtesy of GENERAL MOTORS CORP.
  19. Remove the caps from the transmission oil cooler rear pipes and remove the plugs from the junction fittings at the engine flywheel housing.
  20. ALIGN and HAND-START, then tighten ONLY by hand to seat the transmission oil cooler rear pipes to the junction fittings at the engine flywheel housing.

    Tighten:  Tighten the transmission oil cooler rear pipes to junction fittings at engine flywheel housing to 27 N.m (20 lb ft).

    21. Fig 9: Park/Neutral Position Switch Electrical Connectors
    GM205288Courtesy of GENERAL MOTORS CORP.
  21. Install the transmission wiring harness to LH side of transmission case retaining bolt.

    Tighten:  Tighten the transmission wiring harness to LH side of transmission case retaining bolt to 2.5 N.m (22 lb in).

  22. Connect the park/neutral position switch electrical connectors.
    23. Fig 10: View Of Transmission Harness 20-Way Connector
    GM173661Courtesy of GENERAL MOTORS CORP.
  23. Connect the transmission harness 20-way connector.

    Align the arrows on each half of the connector and insert straight down.

    24. Fig 11: Wiring Harness Retainer To Stud At Differential Rear Cover
    GM71409Courtesy of GENERAL MOTORS CORP.
  24. Connect the wiring harness clip to the top of the differential.
  25. Connect the wiring harness retainer to the stud at the differential rear cover.
    26. Fig 12: Vehicle Speed Sensor (VSS) Electrical Connector
    GM180649Courtesy of GENERAL MOTORS CORP.
  26. Connect the vehicle speed sensor (VSS) electrical connector.
    27. Fig 13: View Of Transaxle Mount Bracket & Bolts
    GM71501Courtesy of GENERAL MOTORS CORP.
  27. Slowly raise the driveline to final installation height.
  28. Remove the jack which supported the engine.
  29. Remove the tie-off retainers from the axle shafts.
  30. CAREFULLY align and seat the axle shafts to the differential.
  31. Install the transaxle mount and bracket to the differential.
  32. Install the transaxle mount bracket to differential bolts.

    Tighten:  Tighten the transaxle mount bracket to differential bolts to 50 N.m (37 lb ft).

    33. Fig 14: View Of Rear Suspension Crossmember
    GM180638Courtesy of GENERAL MOTORS CORP.
  33. With the aid of an assistant, begin to raise the rear suspension crossmember (still firmly attached to a transmission jack), to the vehicle frame rails.
  34. Guide the rear suspension crossmember alignment pins into the alignment holes in the vehicle frame rails, and guide the transaxle mount studs into the mounting holes in the crossmember, then raise the crossmember to seat to the frame rails.
    35. Fig 15: View Of Jack Supports
    GM180637Courtesy of GENERAL MOTORS CORP.
  35. Using ONLY HAND TOOLS, install NEW rear suspension crossmember mounting nuts.

    Tighten:  Tighten the rear suspension crossmember mounting nuts to 110 N.m (81 lb ft).

    36. Fig 16: View Of Transaxle Mount-To-Rear Crossmember Nuts
    GM180633Courtesy of GENERAL MOTORS CORP.
  36. Remove the transmission jack from the rear suspension crossmember.
  37. Release the J 42055  from the transmission, then remove the J 42055  and transmission jack.
  38. Install the transaxle mount to rear suspension crossmember nuts.

    Tighten:  Tighten the transaxle mount to rear suspension crossmember nuts to 50 N.m (37 lb ft).

  39. Install the differential to transmission lower nut.

    Tighten:  Tighten the differential to transmission lower nut to 50 N.m (37 lb ft).

  40. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
    41. Fig 17: View Of Shock Absorber Mounting To Control Arm
    GM180606Courtesy of GENERAL MOTORS CORP.
  41. Support the lower control arm with a jack.
  42. Connect the lower ball joint to the suspension knuckle. Refer to Knuckle Replacement in Rear Suspension.
  43. Install the shock absorber lower mounting bolt.

    Tighten:  Tighten the rear shock absorber lower mounting bolt to 220 N.m (162 lb ft).

  44. Connect the outer tie rod end to the suspension knuckle. Refer to Tie Rod Replacement (Outer End) or Tie Rod Replacement (Suspension Link) in Rear Suspension.
  45. Remove the jack from the suspension control arm.
  46. Repeat steps 40 through 45 for the other side of the vehicle.
  47. Install the rear transverse spring. Refer to Rear Transverse Spring Replacement in Rear Suspension.
    48. Fig 18: Wiring Harness & Driveline Support Assembly
    GM71407Courtesy of GENERAL MOTORS CORP.
  48. Carefully pull the wiring harness down into the L-shaped brackets along the driveline support assembly, align the harness retainer (locator) (1) to the hole in the forward bracket, then secure in place.
    49. Fig 19: Transmission Shift Lever
    GM173669Courtesy of GENERAL MOTORS CORP.
  49. Install the transmission shift cable and bracket into position.
  50. Connect the transmission shift cable to the transmission shift lever.

    Press to secure the cable.

    51. Fig 20: Transmission Shift Cable Bracket & Bolts
    GM71443Courtesy of GENERAL MOTORS CORP.
  51. Install the nuts retaining the transmission shift cable bracket to the transmission.

    Tighten:  Tighten the transmission shift cable bracket retaining nuts to 20 N.m (15 lb ft).

    52. Fig 21: View Of Propeller Shaft Hub Clamp Bolt
    GM173641Courtesy of GENERAL MOTORS CORP.
  52. HAND-TIGHTEN the propeller shaft hub clamp bolt (1) until FINGER-TIGHT.
    53. Fig 22: Propeller Input Shaft Front Bearing Positioning Bolts
    GM173638Courtesy of GENERAL MOTORS CORP.
  53. Remove the propeller input shaft front bearing positioning bolts (M10 - 1.5 X 55 mm) from the driveline support assembly.
  54. Install the two plug bolts to the front of the driveline support assembly.

    Tighten:  Tighten the driveline support assembly front plug bolts to 50 N.m (37 lb ft).

    55. Fig 23: Driveline Tunnel Closeout Panel & Muffler Assemblies
    GM180595Courtesy of GENERAL MOTORS CORP.
  55. Install the driveline tunnel closeout panel. Refer to Driveline Tunnel Closeout Panel Replacement in Propeller Shaft.
  56. Remove the tie-off retainer from the LH muffler assembly.
  57. Install the RH muffler assembly. Refer to Muffler Replacement - Right in Engine Exhaust.
  58. Install the catalytic converters. Refer to Catalytic Converter Replacement in Engine Exhaust.
  59. Install the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  60. Lower the vehicle.
  61. Connect the negative battery cable.

    Tighten:  Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

  62. Program the transmitters. Refer to Transmitter Programming in Keyless Entry.
    63. IMPORTANT: The following steps MUST be performed in order to provide proper alignment of the propeller shaft hub, the propeller input shaft and the propeller input shaft front bearing.
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.