SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 14 (DRIVE AXLES)REMOVAL & INSTALLATIONDIFFERENTIAL ASSEMBLYINSTALLATION (MANUAL TRANSMISSION)
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Installation (Manual Transmission)

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation (Manual Transmission)
WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Slowly slide the differential to the transmission. See Figure.
  2. Install the differential-to-transmission bolts and nuts. Tighten the differential-to-transmission bolts and nuts to specification. See TORQUE SPECIFICATIONS .
  3. Loosely install a rubber band onto the transmission shift rod and position just behind the shift rod clamp. See Fig 1. The rubber band will be used to aid in installing the shift control assembly after the driveline has been installed.
    Fig 1: Identifying Transmission Shift Rod (M/T)
    G00250001Courtesy of GENERAL MOTORS CORP.
  4. Using a piece of masking tape, or similar tape which can be easily broken, affix the transmission shift rod to the driveline support assembly and position the rod just to the outside of the mounting boss used for the shift control. The tape is intended to keep the shift rod in position to aid in shift control installation after the driveline has been installed.
  5. Position the chainfall, or equivalent lifting device, in a way which will protect the rear exhaust hangers located on the driveline support assembly.
  6. Using the lifting device, raise the driveline off the workbench and position the driveline with the Transmission Support Fixture (J 42055) onto a transmission jack.
  7. Connect the Transmission Support Fixture to the transmission jack.
  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. Have an assistant begin to insert the propeller input shaft into the clutch driven plate 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. Insert a putty knife, or similar tool, between the edge of the shifter bracket on the side of the driveline support assembly and the brake pipe retainer on the wall of the driveline tunnel.
  15. Slowly seat the driveline to the engine flywheel housing while maintaining the proper angle of the driveline.
  16. Reposition the wiring harness bracket from near the driveline tunnel wall to align with the appropriate driveline support assembly bolt hole.
  17. Install the driveline support assembly-to-engine flywheel housing bolts. Tighten the driveline support assembly-to-engine flywheel housing bolts to specification. See TORQUE SPECIFICATIONS .
  18. Install the wiring harness to the wiring harness retainer along the top of the transmission.
  19. Slowly raise the driveline to approximately 2" (51 mm) below the final installed height.
  20. Connect the transmission fluid temperature sensor electrical connector, if equipped. See Figure.
  21. Connect the gear select (skip shift) solenoid electrical connector.
  22. Connect the reverse lockout solenoid electrical connector.
  23. Connect the backup lamp switch electrical connector.
  24. Connect the wiring harness clip to the top of the differential. See Figure.
  25. Connect the wiring harness retainer to the stud at the differential rear cover.
  26. Connect the Vehicle Speed Sensor (VSS) electrical connector. See Figure.
  27. Slowly raise the driveline to final installation height.
  28. Remove the putty knife, if still in position.
  29. Remove the jack which supported the rear of the engine.
  30. Remove the tie-off retainers from the axle shafts.
  31. Carefully align and seat the axle shafts to the differential.
  32. Install the transaxle mount with bracket to the differential. See Figure.
  33. Install the transaxle mount bracket-to-differential bolts. Tighten the transaxle mount bracket-to-differential bolts to specification. See TORQUE SPECIFICATIONS .
  34. 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.
  35. 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.
  36. Using only hand tools, install NEW rear suspension crossmember mounting nuts. Tighten the rear suspension crossmember mounting nuts to specification. See TORQUE SPECIFICATIONS .
  37. Remove the transmission jack from the rear suspension crossmember.
  38. Release the Transmission Support Fixture from the transmission, then remove the Transmission Support Fixture and transmission jack.
  39. Install the transaxle mount-to-rear suspension crossmember nuts. Tighten the transaxle mount-to-rear suspension crossmember nuts to specification. See TORQUE SPECIFICATIONS .
  40. Install the differential-to-transmission lower nut. Tighten the differential-to-transmission lower nut to specification.
  41. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
  42. Support the lower control arm with a jack.
  43. Connect the lower ball joint to the suspension knuckle. Tighten lower control arm ball joint stud nut to specification in 3 increments. See TORQUE SPECIFICATIONS .
  44. Install the rear shock absorber lower mounting bolt. Tighten the rear shock absorber lower mounting bolt to specification.
  45. Connect the outer tie rod end to the suspension knuckle. Tighten outer tie rod end nut to specification in 3 increments. See TORQUE SPECIFICATIONS .
  46. Remove the straight jack from the suspension control arm.
  47. Repeat steps  42- 46 for opposite side of vehicle.
  48. Install the rear transverse spring. See appropriate REAR - CORVETTE article in SUSPENSION.
  49. Carefully pull the wiring harness down into the L-shaped brackets along the driveline support assembly, align the harness retainer to the hole in the forward bracket, then secure in place. See Figure.
    50. CAUTION: DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.
  50. Connect the clutch actuator cylinder hose to the clutch master cylinder hose. Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.
  51. Check the clutch hydraulic hoses for twists or kinks.
  52. Install the clutch actuator cylinder hose to the hose retaining clip (at the rear of the engine).
  53. Install the driveline tunnel closeout panel and tighten bolts to specification. See Figure.
  54. Remove the tie-off retainers from the muffler assemblies.
  55. Install the catalytic converter assembly. See CATALYTIC CONVERTERS .
  56. Install the rear tire and wheel assemblies and tighten the wheel lug nuts to specification. See TORQUE SPECIFICATIONS .
  57. Lower the vehicle.
  58. Connect the clutch master cylinder pushrod to the clutch pedal.
  59. Install the clutch master cylinder pushrod retainer.
  60. Install the left instrument panel lower insulator panel.
  61. Grasp the transmission shift rod and pull up to break the masking tape installed earlier to maintain position during installation.
  62. Stretch the rubber band, while still installed onto the transmission shift rod, over the rear stud on top of the driveline tunnel to aid in shift control installation. See Fig 2.
    Fig 2: Installing Shift Control Assembly (M/T)
    G00250002Courtesy of GENERAL MOTORS CORP.
  63. Install the shift control assembly. See Figure.
  64. Break and remove the rubber band.
  65. Install the shift control closeout boot. Check that the closeout boot fully seats to the shift control lever seal and the base of the shift control assembly.
  66. Install the shift control closeout boot retaining nuts. Tighten the shift control closeout boot retaining nuts to specification. See TORQUE SPECIFICATIONS .
  67. Install the instrument panel accessory trim plate.
  68. Install the shift control boot over the shift control lever.
  69. Align the shift control boot to the IP accessory trim plate opening, then press to lock the boot retaining tabs.
  70. Adjust the shape of the boot for appearance, if necessary.
  71. Screw the shift control knob onto the shift control lever until the knob bottoms out. See Figure.
  72. Unscrew the shift control knob just enough to align the retainer slot with the slot on the shift control lever.
  73. Install the shift control knob retainer into the slots and seat fully. See Figure.
  74. Install the shift control knob button.
  75. Install the console.
  76. Connect the negative battery cable and tighten bolt to specification. See TORQUE SPECIFICATIONS .
  77. Program the Remote Keyless Entry (RKE) transmitters. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT.
  78. Fill and bleed the clutch hydraulic system.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.