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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 587 (FRONT SUSPENSION SYSTEM)REPAIR INSTRUCTIONSCROSSMEMBER REPLACEMENT - FRONT SUSPENSIONINSTALLATION PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Installation Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION 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: View Of Front & Rear Crossmember Nuts
    GM581372Courtesy of GENERAL MOTORS CORP.
  1. Raise the crossmember to the vehicle.
    1. Align the crossmember dowel pins to the frame rails.
    2. Align the engine mount studs.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install new crossmember mounting nuts.

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

  3. Install the engine mount lower nuts. Refer to one of the following procedures:
    4. Fig 2: View Of Rear Wheel Speed Sensor Harness Connector
    GM581404Courtesy of GENERAL MOTORS CORP.
  4. Fasten the wheel speed sensor wiring harness retaining clips to the crossmember.
  5. Fasten the brake pipe to the retaining clips on the crossmember.
    6. Fig 3: Electrical Harness & Brake Pipe
    GM581567Courtesy of GENERAL MOTORS CORP.
  6. Connect the electrical harness to the clips on the crossmember.
  7. Connect the brake pipe to the clips on the crossmember.
    8. Fig 4: Removing/Installing Transverse Spring Using J 33432-A
    GM65337Courtesy of GENERAL MOTORS CORP.
  8. Install the transverse spring with the J 33432-A  connected, to the crossmember. See Special Tools and Equipment . Refer to Front Transverse Spring Replacement .
    9. Fig 5: Lower Control Arm & Outer Tie Rod Ball Stud
    GM65333Courtesy of GENERAL MOTORS CORP.
  9. Install the lower control arm to the crossmember. Refer to Lower Control Arm Replacement .
    10. Fig 6: Lower Shock Absorber & Bolts
    GM65335Courtesy of GENERAL MOTORS CORP.
  10. Install the shock absorbers to the lower control arms.

    Tighten:  Tighten the shock absorber lower mounting nuts to 28 N.m (21 lb ft).

    11. Fig 7: Power Steering Gear & Mounting Bolts
    GM65352Courtesy of GENERAL MOTORS CORP.
  11. Install the power steering gear to the crossmember.

    Tighten:  Tighten the power steering gear mounting bolts to 100 N.m (74 lb ft).

  12. Install the bolts to the brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Antilock Brake System.
  13. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
    14. Fig 8: ESC Sensor Link
    GM581252Courtesy of GENERAL MOTORS CORP.
  14. Install the steering linkage outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering Systems.
  15. Connect the ESC sensor links to the upper control arm, if equipped.
    16. Fig 9: Shock Absorber ESC Harness Connector
    GM581266Courtesy of GENERAL MOTORS CORP.
  16. Connect the shock absorber solenoid electrical connector, if equipped.
  17. Install the stabilizer shaft to the vehicle. Refer to Stabilizer Shaft Replacement .
  18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  19. Lower the vehicle.
  20. Remove J 41803  andJ 28467-B  from the engine. See Special Tools and Equipment .
  21. Install the generator. Refer to Generator Replacement in Engine Electrical.
  22. Install the washer pump/reservoir. Refer to Washer Solvent Container Replacement in Wipers/Washer Systems.
    23. Fig 10: Engine Coolant Temperature Switch Electrical Connector
    GM581199Courtesy of GENERAL MOTORS CORP.
  23. Install the engine coolant temperature switch electrical connector.
  24. Install the front headlamp electrical connector.
  25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  26. Perform a vehicle front end alignment. Refer to Measuring Wheel Alignment in Wheel Alignment.
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.