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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 227 (PROPELLER SHAFT AND UNIVERSAL JOINTS)REPAIR INSTRUCTIONSPROPELLER SHAFT BOOT REPLACEMENTINSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Installation Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2003 GMC Savana Special, 2003 GMC Savana Camper Special, 2003 GMC Savana, 2003 Chevrolet RV Cutaway, and 2003 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean the splines of the rear inner tube (6) and the outer tube (1).
  2. Inspect the outer and inner splines for damage. Replace the propeller shaft assembly if necessary.
  3. Apply grease, GM P/N 12345879 (Canadian P/N 109535511) or equivalent, to the splines of the rear inner tube (6).
  4. Install the bushing (3) on the outer tube (1). The flanged end of the bushing should be toward the rear of the vehicle.
  5. Install the 81.5 mm clamp (5) onto the rear inner tube (6). The size is stamped on the clamp.
  6. Install the 86.5 mm clamp (2) on the large diameter end of the boot (4). The size is stamped on the clamp.
    Fig 1: Installing Bushing & Clamps
    G01216279Courtesy of GENERAL MOTORS CORP.
  7. Slide the boot (4) onto the rear inner tube (6), small diameter end toward the rear of the vehicle.
  8. Install the 81.5 mm clamp (5) onto the boot (4).

    Important:  The rear inner tube and outer tube splines are not keyed. It is important to observe the alignment marks made during removal during the installation process.

  9. Utilizing the alignment marks made during removal, reassemble the rear inner tube to the outer tube.
  10. Wipe off the excess grease from the tubes.
  11. Install the propeller shaft to the rear axle pinion axle. Align the shaft and the yoke using the marks made during removal.
  12. Install the yoke retainers and the bolts.
  13. Using the J 43218  or equivalent, crimp the outer tube clamp.
    Fig 2: Installing Propeller Shaft To Rear Axle Pinion Axle
    G01216280Courtesy of GENERAL MOTORS CORP.
  14. Adjust the boot (4) length so that it is 124-134 mm (4.88-5.28 in) from end to end.
  15. Using the J 43218  or equivalent, crimp the rear inner tube side clamp.
  16. Lower the vehicle.
    Fig 3: Adjusting Boot Length
    G01216281Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

NO RELATED

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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.