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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 154 (AUTOMATIC TRANSMISSION SERVICING)REMOVAL & INSTALLATIONCASE SIDE COVERINSTALLATION
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Case Side Cover: Installation

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Apply Transjel(tm) Lubricant (J-36850) to the case side cover "O" ring (59). See Figure . Install the "O" ring (59) to the case side cover. Install the case side cover gasket (54).
  2. Install the case side cover (53). Install the case side cover bolts. See Figure . Tighten bolts to specification. See TORQUE SPECIFICATIONS  . Remove the drain pan from under the transaxle.
  3. Install the wiring harness connectors. Use the utility stand in order to raise the left side of the frame. Install the NEW left side frame bolts. Install the NEW right side frame bolts. Install the engine mount lower nuts.
  4. Install the transaxle mount and bracket. See TRANSAXLE MOUNT & BRACKET  . Tighten the bolts to specification. See TORQUE SPECIFICATIONS  . Lower the vehicle.
  5. Remove the utility stand support from the right side of the frame. Remove the utility stand support from the left side of the frame. Connect the catalytic converter pipe to the right (rear) exhaust manifold.
  6. Install the intermediate shaft to the steering gear. See appropriate POWER RACK & PINION article in STEERING.
    CAUTION: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
  7. Install the left drive axle to the transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Install the left lower ball joint to the left steering knuckle. See appropriate FRONT article in SUSPENSION.
  8. Install the wheel speed sensor harness connector. Install the left tie rod end to the steering knuckle. Install the stabilizer shaft links to the lower control arms. See appropriate FRONT article in SUSPENSION.
  9. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle. Install the engine mount struts. See appropriate REMOVAL & INSTALLATION article.
  10. Remove the engine support fixture. Remove the throttle body air inlet duct. Connect the negative battery cable.
  11. Fill transaxle with appropriate fluid to proper level. See LUBRICATION  . Inspect for fluid leaks. Inspect for proper completion of the repairs. Inspect for fluid leaks.
    CAUTION: DO NOT overfill the transaxle. Overfilling will result in foaming, loss of fluid, and possible damage to the transaxle.
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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.