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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 48 (REAR DRIVE AXLE)REPAIR INSTRUCTIONSREAR AXLE REPLACEMENT (25 SERIES)INSTALLATION PROCEDURE
2008 Chevrolet Chevy Express G3500, Van Passenger Extended

Installation Procedure

2008 Chevrolet Chevy Express G3500, Van Passenger ExtendedSECTION Installation Procedure
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Rear Axle, Spacers, Spring Plates & U-Bolts
    GM348393Courtesy of GENERAL MOTORS CORP.
  1. Place the rear axle assembly under the vehicle.
  2. Align the rear axle assembly with the springs.
  3. Connect the spacers, the spring plates and the U-bolts to the rear axle.
  4. Raise the rear axle assembly into position.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the washers if equipped and the nuts to the U-bolts.

    Tighten:  Tighten the nuts to 72 N.m (53 lb ft).

  6. Install the vent hose to the rear axle vent fitting. Refer to Vent Hose Replacement .
  7. Connect the shock absorbers to the rear axle. Refer to Shock Absorber Replacement (1500 Series) or Shock Absorber Replacement (2500 Series) .
  8. Install the brake calipers. Refer to Rear Brake Caliper Replacement (1500 Series) or Rear Brake Caliper Replacement (2500 Series) .
  9. Install the brake lines and the brake line bracket bolts to the axle.
  10. Connect the parking brake cable. Refer to Park Brake Cable Replacement - Left Rear and Park Brake Cable Replacement - Right Rear .
  11. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  12. Connect the propeller shaft. Refer to Rear Propeller Shaft Replacement .
  13. Fill the axle with lubricant. Use the proper fluid. Refer to Lubricant Replacement - Rear Drive Axle (8.6 Inch Axle)  or Lubricant Replacement - Rear Drive Axle (9.5 Inch LD Axle)  or Lubricant Replacement - Rear Drive Axle (9.5 Inch HD Axle) .
  14. Remove the utility stands.
  15. 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.