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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G3500, VAN PASSENGER EXTENDEDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 564 (PROPELLER SHAFT AND UNIVERSAL JOINTS)REPAIR INSTRUCTIONSPROPELLER SHAFT BOOT 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 does not describe the selected car, but rather 6 other vehicles, including the 2009 GMC Savana Special, 2009 GMC Savana Camper Special, 2009 GMC Savana, 2009 Chevrolet RV Cutaway, and 2009 Chevrolet Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Propeller Shaft Boot Rear Inner Tube & Clamps
    GM847877Courtesy of GENERAL MOTORS CORP.
  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.
  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).
    NOTE: 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. Fig 2: Identifying Driveshaft Pinion, Yoke Retainers & Bolts
    GM361391Courtesy of GENERAL MOTORS CORP.
  11. Install the propeller shaft (3) to the rear axle pinion yoke (4). Align the shaft and the yoke using the marks made during removal.
    12. CAUTION: Refer to Fastener Caution .
  12. Install the yoke retainers (2) and the bolts (1) and tighten to 25 N.m (18 lb ft).
  13. Using the J 43218  or equivalent, crimp the outer tube clamp. See Special Tools .
    14. Fig 3: Propeller Shaft Boot Rear Inner Tube & Clamps
    GM847877Courtesy 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. See Special Tools .
  16. 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.