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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 18 (AUTOMATIC TRANSAXLE SERVICING)REMOVAL & INSTALLATIONCASE EXTENSION HOUSINGINSTALLATION
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Case Extension Housing: Installation

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation
WARNING: This page is about a different car, the 2003 Cadillac Seville and 2003 Cadillac DeVille. However, it is still accessible from the selected car via links, so may be relevant.
  1. Inspect the scavenge tube (54) for damage and clogging. See Figure . Install the scavenge tube seal into the case. See Figure . Install the scavenge tube into the scavenge tube seals, located in the case and in the driven sprocket support.
  2. Tap the scavenge tube lightly with a plastic hammer to ensure a tight fit in both seals. Install the scavenge tube bolt (15). Tighten the bolt to specification. See TORQUE SPECIFICATIONS  . Inspect the case to case extension seal (126). See Figure .
  3. Inspect the case extension mating surface for damage. Install the following parts:
    • The selective washer (133).
    • The thrust washer (132).
    • The case extension seal (126).
    • The case extension (134).
  4. Apply Pipe Thread Sealant (GM P/N 12346004) to bolt threads before installation. Install the case extension bolts (128 and 129). See Figure . Hand tighten the bolts (128 and 129) until the case extension is seated onto the case. Install the long Dial Indicator Mounting Post (J-25025-7A) and the Dial Indicator Set (J-8001). See Fig 1 .
  5. Position the dial indicator with the stem contacting the output shaft. Set the dial indicator to zero. Insert the screwdriver through the vehicle speed sensor bore and lift the speed sensor rotor for measurement. Protect the bore with a piece of wood or a suitable piece of plastic.
  6. Proper end play clearance is 0.006-0.026" (0.15-0.65 mm). Record the measured specification and, if necessary, adjust the clearance with the proper thickness selective thrust washer and reassemble. See Fig 1 . Remove the dial indicator set and the post.
  7. Install the stud (127). See Figure . Tighten the bolt (128) and the stud (127) to 37-40 ft. lbs. (50-55 N.m). Tighten the bolt (129) to 15-20 ft. lbs. (20-27 N.m). Install the vehicle speed sensor. See VEHICLE SPEED SENSOR  . Install the ground wire to case.
  8. Install the transaxle brace. See TRANSAXLE BRACE  . Install the bolts securing the front transaxle brace to the transaxle and right cylinder head. Install the wiring harness. Install the right drive axle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES.
  9. Remove the safety stands. Lower the vehicle. Fill transaxle with appropriate fluid to proper level. See LUBRICATION  .
Fig 1: Measuring Final Drive End Play
G94B37086Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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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.