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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 746 (REAR SUSPENSION SYSTEM)REPAIR INSTRUCTIONSCROSSMEMBER REPLACEMENTINSTALLATION 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 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Lower Ball Joint Stud Nut, Suspension Knuckle & Inner CV Joints
    GM171212Courtesy of GENERAL MOTORS CORP.
  1. Install the crossmember to the vehicle.
    • Align the crossmember dowel pins to the holes in the frame rails.
    • Align the transaxle mount studs to the crossmember.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install NEW rear suspension crossmember mounting nuts.

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

  3. Remove the transmission jack from the transmission pan.
  4. Connect all electrical connectors to the crossmember.
  5. Connect the brake pipes to the retainers in the crossmember.
  6. Install the transaxle mount lower nuts. Refer to Transmission Mount Replacement in Rear Drive Axle.
  7. Install the inner constant velocity (CV) joints to the differential. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  8. Install the rear suspension knuckles to the lower control arms. Refer to Knuckle Replacement .
  9. Install the shock absorbers to the lower control arms. Refer to Shock Absorber Replacement (W/O F55)  or Shock Absorber Replacement (W/F55) .
  10. Install the outer tie rod end studs into the rear suspension knuckles. Refer to Tie Rod Replacement (Outer End)  or Tie Rod Replacement (Suspension Link) .
  11. Install the stabilizer shaft to the crossmember. Refer to Stabilizer Shaft Replacement .
  12. Remove the jack stands from under the lower control arms.
  13. Install the transverse spring to the crossmember. Refer to Rear Transverse Spring Replacement .
    14. Fig 2: View Of Rear Wheel Speed Sensor Harness Connector
    GM581404Courtesy of GENERAL MOTORS CORP.
  14. Connect the electrical connectors to the wheel speed sensors.
    15. Fig 3: Shock Absorber ESC Harness Connector
    GM581266Courtesy of GENERAL MOTORS CORP.
  15. Connect the shock absorber solenoid connectors, if equipped.
    16. Fig 4: ESC Position Sensor Links
    GM583226Courtesy of GENERAL MOTORS CORP.
  16. Connect the ESC position sensor links, if equipped.
    17. Fig 5: Measuring The Spring Stud Height
    GM200316Courtesy of GENERAL MOTORS CORP.
  17. Set the spring stud height (1) to the measurement taken before removal.
  18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  19. Lower the vehicle.
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.