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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 540 (FRAME AND UNDERBODY)REPAIR INSTRUCTIONSFRAME REPLACEMENT - FRONT (W/AWD)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation Procedure
WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. If you are REPLACING the frame, perform the following steps:
    1. Install the power steering cooler pipes to the frame. Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
    2. Install the lower control arms to the frame. Refer to Lower Control Arm Replacement in Front Suspension.
    3. Install the frame insulators to the frame. Refer to Frame Cushion or Insulator Replacement - Front .
    2. Fig 1: View Of Transmission Stand Supporting Powertrain
    GM1388666Courtesy of GENERAL MOTORS CORP.
  2. Use a utility stand with the frame around it to support the powertrain.
    3. Fig 2: View Of Utility Stand Supporting Powertrain At Transfer Case
    GM1388693Courtesy of GENERAL MOTORS CORP.
  3. Remove the transmission stand from the powertrain.
  4. Install the frame to the vehicle.
  5. Use the utility stand to raise the frame and powertrain.
    IMPORTANT: Ensure that the alignment pins remain installed during the frame installation.
  6. Insert two 19 mm (0.75 in) diameter X 203 mm (8 in) long guide pins or drill bits into the frame right side alignment holes in order to align the frame.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    7. Fig 3: Locating Frame To Body Bolts
    GM478740Courtesy of GENERAL MOTORS CORP.
  7. Install the frame to chassis front bolts.

    Tighten:  Tighten the bolts to 155 N.m (114 lb ft).

  8. Install the frame to chassis rear bolts.

    Tighten:  Tighten the bolts to 240 N.m (177 lb ft).

  9. Remove the alignment pins from the frame.
  10. Install the transaxle mount nuts.

    Tighten:  Tighten the nuts to 47 N.m (35 lb ft).

  11. Install the engine mount nuts.

    Tighten:  Tighten the nuts to 47 N.m (35 lb ft).

  12. Remove the utility stand from the powertrain.
    13. Fig 4: Supporting Frame & Powertrain
    GM1388664Courtesy of GENERAL MOTORS CORP.
  13. Use a utility stand to support the frame.
  14. Remove the rear frame bolts.
  15. Use the utility stand in order to lower the frame and powertrain.
  16. Connect the wheel speed sensor wiring harnesses to the lower control arms.
  17. Connect the wheel speed sensor harness connectors.
  18. Connect the lower control arms to the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  19. Connect the power steering cooler pipe to the pressure hose. Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
  20. Install front fender liner. Refer to Front Fender Liner Replacement in Exterior Trim.
  21. Install the power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
  22. Install the catalytic converter pipe. Refer to Catalytic Converter Replacement in Engine Exhaust.
  23. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
  24. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
  25. Install the front engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
  26. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  27. Lower the vehicle.
  28. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.4L or Engine Support Fixture in Engine Mechanical - 3.6L (LY7).
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.