Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 186 (FRAME AND UNDERBODY)REPAIR INSTRUCTIONSREAR FRAME REPLACEMENTINSTALLATION PROCEDURE

2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure

WARNING: This page is about a different car, the 2008 Cadillac STS. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Rear Frame Assembly

Courtesy of GENERAL MOTORS CORP.

With the aid from an assistant, position and secure the new rear frame on the engine support fixture.
Install the following components to the rear frame assembly:
- Differential Replacement
- Rear Brake Rotor Replacement
- Rear Brake Caliper Replacement (JE5, JL9) or Rear Brake Caliper Replacement (J56)
- Stabilizer Shaft Link Replacement
- Trailing Arm Replacement
- Adjustment Link Replacement
- Stabilizer Shaft Replacement
- Parking Brake Rear Cable Replacement - Left Side or Parking Brake Rear Cable Replacement - Right Side
- The rear brake pipes
- Upper Control Arm Replacement
- Lower Control Arm Replacement
- Headlamp Leveling Rear Suspension Height Sensor Replacement

IMPORTANT: The rear coil springs need to be indexed into the lower spring insulators prior to assembly.

Index the rear coil springs to the spring insulators.

IMPORTANT: Ensure the intermediate brake cable is clear of the front frame to body mount prior to securing the frame bolts.

Ensure the intermediate park brake cable is positioned over left side frame assembly on the left side.
Lower the vehicle to the frame.

Fig 2: View Of Rear Locator Sleeves, Upper Spring Insulator & Coil Springs

Courtesy of GENERAL MOTORS CORP.

Position the coil springs (3) to the upper spring insulator (2).

Fig 3: Removing & Installing Frame-To-Bolt Mounting Bolts & Washers

Courtesy of GENERAL MOTORS CORP.

Index the rear side frame mounts to the rear locator sleeves (1) located on the body.
Lower the vehicle until the frame mounts contact the body rail.

NOTE: Refer to Fastener Notice .

Install the rear frame washers (3) and anchor bolts (4).
Tighten:
- Tighten the front bolts to 265 N.m (195 lb ft).
- Tighten the rear bolts to 191 N.m (141 lb ft).
Raise the vehicle.
Remove the J 39580 . See Special Tools .

Fig 4: Supporting Control Arm Using Support Fixture

Courtesy of GENERAL MOTORS CORP.

Install the support fixture (3) in order to raise the lower control arms for ease of lower shock bolt installation (2).
Install the lower shock bolt.
Tighten: Tighten the bolt (2) to 150 N.m (111 lb ft).
Repeat the above step for the other side.
Remove the support fixture (3).

Fig 5: View Of Rear Park Brake Cable Connector & Intermediate Park Brake Cable

Courtesy of GENERAL MOTORS CORP.

Connect the intermediate park brake cable (2) to the rear park brake cable connector (1).

Fig 6: View Of Park Brake Cable

Courtesy of GENERAL MOTORS CORP.

Connect the intermediate park brake cable (2) to the front park brake cable connector.

Fig 7: View Of Brake Pipe Bracket & Brake Pipe Bracket Studs

Courtesy of GENERAL MOTORS CORP.

Position the brake pipe bracket (2) to the body studs.
Install the brake pipe bracket retaining nuts (1).
Tighten: Tighten the nuts to 10 N.m (89 lb in).

Fig 8: View Of Rear Brake Pipe Lines

Courtesy of GENERAL MOTORS CORP.

Connect the rear brake lines (1) at the forward rear wheelhouse.
Tighten: Tighten the lines to 15 N.m (11 lb ft).

Fig 9: View Of Rear Wheel Speed Sensor Electrical Connectors

Courtesy of GENERAL MOTORS CORP.

Connect the rear WSS electrical connectors.
Secure the electrical harness retainer clips to the park brake cables.
Install the rear wheels. Refer to Tire and Wheel Removal and Installation .
Install the rear suspension bracket. Refer to Rear Suspension Bracket Replacement .
Lower the vehicle.
Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) .
Align the vehicle. Refer to Wheel Alignment Measurement .

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.