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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 916 (FRAME AND UNDERBODY)REPAIR INSTRUCTIONSENGINE FRONT CROSSMEMBER REPLACEMENT (4WD)INSTALLATION 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 does not describe the selected car, but rather 6 other vehicles, including the 2007 GMC Savana Special, 2007 GMC Savana Camper Special, 2007 GMC Savana, 2007 Chevrolet RV Cutaway, and 2007 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Engine Crossmember Upper Mounting Bolts
    GM851506Courtesy of GENERAL MOTORS CORP.
  1. Install the engine crossmember.
  2. Install the lower control arm bolts to the through the engine crossmember and frame.
    3. NOTE: Refer to FASTENER NOTICE .
  3. Install the lower control arm nuts and washers.

    Tighten:  Tighten the nuts to 145 N.m (107 lb ft).

  4. Connect the electrical wiring harness connectors to the engine crossmember.
  5. Install the engine crossmember upper mounting bolts. Do not tighten.
    6. Fig 2: Engine Crossmember Lower Mounting Bolts & Nuts
    GM851512Courtesy of GENERAL MOTORS CORP.
  6. Install the engine crossmember lower mounting bolts and nuts.

    Tighten:  Tighten the upper and lower engine crossmember bolts to 65 N.m (48 lb ft).

    7. Fig 3: Engine Crossmember From Left Lower Control Arm Bracket Bolt
    GM1199377Courtesy of GENERAL MOTORS CORP.
  7. Install the engine crossmember bolt to the left side lower control arm bracket.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

    8. Fig 4: Left Side Differential Carrier Lower Mounting Bracket Bolt
    GM1199441Courtesy of GENERAL MOTORS CORP.
  8. Install the left side differential carrier lower mounting bracket bolt.

    Tighten:  Tighten the bolt to 85 N.m (63 lb ft).

    9. Fig 5: Right Side Differential Carrier Lower Mounting Bracket Bolt & Nut
    GM1199447Courtesy of GENERAL MOTORS CORP.
  9. Install the right side differential carrier lower mounting bracket bolt and nut.

    Tighten:  Tighten the bolt to 85 N.m (63 lb ft).

  10. Load the torsion bars. Refer to Torsion Bar and Support Assembly Replacement .
  11. Remove the supports from the lower control arms.
  12. 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.