Front Suspension System Chevrolet Chevy Express G3500

Fastener Tightening Specifications

Fastener Tightening Specifications

Scheme 1

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the stabilizer shaft links. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
4. Remove the stabilizer shaft insulator clamps mounting bolts (4) (15 and 25 series).
5. Remove the stabilizer shaft clamps (3) (1500 and 2500 series w/7300 GVW).
6. Remove the stabilizer shaft (5) (1500 and 2500 series w/7300 GVW).
7. Remove the stabilizer shaft insulators (2) (1500 and 2500 series w/7300 GVW).
8. Remove the stabilizer shaft insulator clamps mounting nuts (3) and/or studs (2500 series w/8500 and 8600 GVW and 3500 series).
9. Remove the stabilizer shaft clamps (4) (2500 series w/8500 and 8600 GVW and 3500 series).
10. Remove the stabilizer shaft (2) (2500 series w/8500 and 8600 GVW and 3500 series).
11. Remove the stabilizer shaft insulators (5) (2500 series w/8500 and 8600 GVW and 3500 series).
12. Inspect all of the parts for wear and damage.

Installation Procedure

1. Install the stabilizer shaft insulator clamp studs, if removed (2500 series w/8500 and 8600 GVW and 3500 series). Tighten: Tighten the studs to 25 N.m (18 lb ft).
2. Install the stabilizer shaft insulators (5) to the stabilizer shaft (2) (2500 series w/8500 and 8600 GVW and 3500 series).
3. Install the stabilizer shaft (2) (2500 series w/8500 and 8600 GVW and 3500 series).
4. Install the stabilizer shaft clamps (4) over the insulators and the stabilizer shaft (2) (2500 series w/8500 and 8600 GVW and 3500 series).
5. Install stabilizer shaft insulator clamps mounting nuts (3) (2500 series w/8500 and 8600 GVW and 3500 series). Tighten: Tighten the nuts to 46 N.m (34 lb ft).
6. Install the stabilizer shaft insulators (2) (1500 and 2500 series w/7300 GVW).
7. Install the stabilizer shaft (5) (1500 and 2500 series w/7300 GVW).
8. Install the stabilizer shaft clamps (3) (1500 and 2500 series w/7300 GVW).
9. Install the stabilizer shaft insulator clamps mounting bolts (4) (1500 and 2500 series w/7300 GVW). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Install the stabilizer shaft links. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
11. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
12. Lower the vehicle.

Scheme 2

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the stabilizer shaft nut from the link bolt.
3. Remove the stabilizer shaft link bolt.
4. Remove the stabilizer shaft link insulators and spacers.
5. Inspect all of the parts for wear and damage.

1. Install the stabilizer shaft link insulators and spacers.
2. Perform the following procedure before installing the stabilizer shaft link bolts. Remove all traces of the original adhesive patch. Apply Threadlocker GM P/N 12345382 or BLUE LOCTITE™ #242 on the threads of the bolts.
3. Install the stabilizer shaft link bolts.
4. Install the stabilizer shaft nut to the link bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
5. Remove the safety stands
6. Lower the vehicle.

Removal Procedure

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the stabilizer shaft insulator clamps mounting bolts (4) (1500 and 2500 series w/7300 GVW).
3. Remove the stabilizer shaft insulator clamps (3) from the stabilizer shaft insulator (2) (1500 and 2500 series w/7300 GVW).
4. Lower the stabilizer shaft (5) and remove the stabilizer shaft insulator (2) (1500 and 2500 series w/7300 GVW).
5. Remove the stabilizer shaft insulator clamps nuts (3) and/or studs (2500 series w/8500 and 8600 GVW and 3500 series).
6. Remove the stabilizer shaft clamps (4) (2500 series w/8500 and 8600 GVW and 3500 series).
7. Lower the stabilizer shaft (2) and remove the stabilizer shaft insulators (5) (2500 series w/8500 and 8600 GVW and 3500 series).
8. Inspect all of the parts for wear and damage.

1. Install the stabilizer shaft insulator clamp studs, if removed (2500 series w/8500 and 8600 GVW and 3500 series). Tighten: Tighten the studs to 25 N.m (18 lb ft).
2. Install the stabilizer shaft insulators (5) to the stabilizer shaft (2) (2500 series w/8500 and 8600 GVW and 3500 series).
3. Install the stabilizer shaft clamps (4) over the insulators and the stabilizer shaft (2) (2500 series w/8500 and 8600 GVW and 3500 series).
4. Install stabilizer shaft insulator clamps nuts (3) (2500 series w/8500 and 8600 GVW and 3500 series). Tighten: Tighten the nuts to 46 N.m (34 lb ft).
5. Install the stabilizer shaft insulator (2) to stabilizer shaft (5) (1500 and 2500 series w/7300 GVW).
6. Install the stabilizer shaft insulator clamps (3) to the stabilizer shaft insulator (2) (1500 and 2500 series w/7300 GVW).
7. Install the stabilizer shaft insulator clamps mounting bolts (4) (1500 and 2500 series w/7300 GVW). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
8. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the lower control arm. Refer to «Lower Control Arm Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system__lower-control-arm-replacement-rwd) or «Lower Control Arm Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system__lower-control-arm-replacement-4wd) .
4. Place the lower control arm in a bench vice.
5. Using a chisel, remove the 4 securing crimps from the ball joint body.
6. Using a press, remove the ball joint from the lower control arm.

1. Install the new ball joint using a press.
2. Place the lower control arm in a bench vice.
3. Using a punch, install 4 crimps to the ball joint. Use the replaced ball joint as a reference.
4. Install the lower control arm. Refer to «Lower Control Arm Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system__lower-control-arm-replacement-rwd) or «Lower Control Arm Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system__lower-control-arm-replacement-4wd) .
5. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
6. Lower the vehicle.
7. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Steering Knuckle Replacement (RWD)

Tools Required

1. J 24319-B Steering Linkage and Tie Rod Puller
2. J 43631 Ball Joint Remover
3. J 45851 Ball Joint Separator Protector Adapters. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .

Scheme 3

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the wheel hub and bearing. Refer to «Wheel Hub, Bearing, and Seal Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) or «Wheel Hub, Bearing, and Seal Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
4. Remove the outer tie rod to steering knuckle retaining nut.
5. Disconnect the outer tie rod from the steering knuckle using J 24319-B .
6. Remove the brake hose bracket retaining bolt from the steering knuckle.
7. Support the lower control arm with a suitable jack.
8. Remove the upper ball joint retaining nut.
9. Disconnect the upper ball joint from the steering knuckle using the J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
10. Remove the lower ball joint retaining nut.
11. Disconnect the lower ball joint from the steering knuckle using the J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
12. Remove the steering knuckle.

Scheme 4

1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end.
2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, the replace the steering knuckle.
3. Install the steering knuckle.
4. Install the lower ball joint to steering knuckle retaining nut. Tighten: Tighten the retaining nut to 100 N.m (74 lb ft).
5. Install the upper ball joint to steering knuckle retaining nut. Tighten: Tighten the retaining nut to 50 N.m (37 lb ft).
6. Install the brake hose bracket retaining bolt to the knuckle. Tighten: Tighten the bolt to 10 N.m (88 lb in).
7. Connect the outer tie rod to the steering knuckle.
8. Install the outer tie rod to the steering knuckle retaining nut. Tighten: Tighten the nut to 63 N.m (47 lb ft).
9. Remove the safety stand.
10. Install the wheel hub and bearing. Refer to «Wheel Hub, Bearing, and Seal Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) or «Wheel Hub, Bearing, and Seal Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
11. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
12. Lower the vehicle.

Steering Knuckle Replacement (4WD)

Tools Required

1. J 24319-B Steering Linkage and Tie Rod Puller
2. J 43631 Ball Joint Remover
3. J 45851 Ball Joint Separator Protector Adapters. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Unload the torsion bars. Refer to «Torsion Bar and Support Assembly Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
4. Remove the wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shaft.
5. Remove the wheel hub and bearing. Refer to «Wheel Hub, Bearing, and Seal Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) or «Wheel Hub, Bearing, and Seal Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
6. Remove the outer tie rod to steering knuckle retaining nut.
7. Disconnect the outer tie rod from the steering knuckle using J 24319-B .
8. Remove the brake hose bracket retaining bolt from the steering knuckle.
9. Remove the upper ball joint retaining nut.
10. Disconnect the upper ball joint from the steering knuckle using the J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
11. Remove the lower control arm retaining nut.
12. Disconnect the lower ball joint from the steering knuckle using the J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
13. Remove the steering knuckle.

Scheme 5

1. Clean all grease and contaminants from the tapered section and the threads of the upper ball joint, the lower ball joint, and the tie rod end.
2. Clean and inspect the taper holes and the mounting surfaces of the steering knuckle. If any of the tapered holes are elongated, out of round, or damaged, replace the steering knuckle.
3. Install the steering knuckle.
4. Install the lower ball joint retaining nut. Tighten: Tighten the retaining nut to 100 N.m (74 lb ft).
5. Install the upper ball joint retaining nut. Tighten: Tighten the retaining nut to 50 N.m (37 lb ft).
6. Install the brake hose bracket to steering knuckle retaining bolt. Tighten: Tighten the retaining bolt to 10 N.m (88 lb in).
7. Connect the outer tie rod to the steering knuckle.
8. Install the outer tie rod retaining nut. Tighten: Tighten the retaining nut to 63 N.m (47 lb in).
9. Install the wheel hub and bearing. Refer to «Wheel Hub, Bearing, and Seal Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) or «Wheel Hub, Bearing, and Seal Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
10. Install the wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shaft.
11. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
12. Load the torsion bars. Refer to «Torsion Bar and Support Assembly Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
13. Lower the vehicle.
14. Align the vehicle. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Upper Control Arm Replacement

Tools Required

1. J 43631 Ball Joint Remover
2. J 45851 Ball Joint Separator Protector Adapters. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .

Scheme 6

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Support lower control arm with a jack stand.
3. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
4. Remove the retaining bolts for the brake hose and the wheel speed sensor brackets.
5. Remove the wheel drive shaft (4WD only). Refer to «Wheel Drive Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
6. Remove the upper ball joint retaining nut.
7. Disconnect the upper control arm from the steering knuckle using the J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
8. Remove the upper control arm nuts and the adjustment cams.
9. Remove the upper control arm bolts.
10. Remove the upper control arm.

Scheme 7

1. Install the upper control arm.
2. Install the upper control arm bolts.
3. Install the upper control arm nuts and the adjustment cams. Tighten: Tighten the nuts to 175 N.m (129 lb ft).
4. Connect the upper control arm to the steering knuckle.
5. Install the new upper ball joint retaining nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
6. Install the wheel drive shaft (4WD only). Refer to «Wheel Drive Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
7. Install the retaining bolts for the brake hose and wheel speed sensor brackets. Tighten: Tighten the brake hose bracket to steering knuckle bolt to 10 N.m (88 lb in). Tighten the brake hose bracket to upper control arm bolt to 10 N.m (88 lb in).
8. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
9. Remove the safety stands.
10. Lower the vehicle.
11. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Lower Control Arm Replacement (RWD)

Tools Required

1. J 43631 Ball Joint Remover
2. J 45851 Ball Joint Separator Protector Adapters. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the front coil spring. Refer to «Front Coil Springs Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
4. Remove the lower ball joint retaining nut.
5. Disconnect the lower ball joint from the steering knuckle using J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
6. Remove the lower control arm.

Scheme 8

1. Install the lower control arm.
2. Connect the lower ball joint to the steering knuckle.
3. Install the lower ball joint retaining nut. Tighten: Tighten the nut to 100 N.m (74 lb ft).
4. Install the front coil spring. Refer to «Front Coil Springs Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
5. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
6. Lower the vehicle.
7. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Lower Control Arm Replacement (4WD)

Tools Required

1. J 43631 Ball Joint Remover
2. J 45851 Ball Joint Separator Protector Adapters. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .

Scheme 9

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the torsion bar. Refer to «Torsion Bar and Support Assembly Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
4. Remove the stabilizer link. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
5. Remove the wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
6. Remove the shock absorber lower retaining nut and bolt.
7. Remove the lower ball joint retaining nut.
8. Disconnect the lower ball joint from the steering knuckle using J 43631 and J 45851 . See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
9. Remove the lower control arm nuts and the washers.
10. Remove the lower control arm bolts.
11. Remove the lower control arm.

1. Install the lower control arm.
2. Connect the lower ball joint to the steering knuckle.
3. Install the lower control arm mounting bolts.
4. Install the lower control arm mounting nuts and the washers. Tighten: Tighten the nuts to 145 N.m (107 lb ft).
5. Install the lower ball joint retaining nut. Tighten: Tighten the nut to 100 N.m (74 lb ft).
6. Install the shock absorber lower retaining nut and bolt. Tighten: Tighten the nut to 80 N.m (59 lb ft).
7. Install the wheel drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
8. Install the stabilizer link. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
9. Install the torsion bar. Refer to «Torsion Bar and Support Assembly Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
11. Lower the vehicle.
12. Check the wheel alignment. Refer to «Measuring Wheel Alignment»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-alignment/#wheel-alignment-specifications-adjustment-procedures__measuring-wheel-alignment) in Wheel Alignment.

Scheme 10

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Unsnap the jounce bumper from the mounting cup.

1. Snap the jounce bumper to the mounting cup.
2. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the shock absorber. Refer to «Shock Absorber Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) or «Shock Absorber Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
4. Remove the front stabilizer shaft link. Refer to «Stabilizer Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
5. Support the lower control arm near the lower ball joint with a suitable safety jack.
6. Install OTC 7045-B coil spring compressor tool or equivalent to the coil spring through the hole in the lower control arm.
7. Compress the front coil spring using OTC 7045-B coil spring compressor tool or equivalent and remove all tension from the lower control arm.
8. Remove the lower control arm pivot bolt retaining nuts and washers.
9. Remove the rear pivot bolt.
10. Remove the front pivot bolt.
11. Lower the lower control arm and remove the coil spring and insulator.
12. Remove the OTC 7045-B coil spring compressor tool or equivalent from the coil spring.
13. Remove the coil spring insulator from the coil spring.

Scheme 11

1. Install the coil spring insulator to the coil spring.
2. Install the OTC 7045-B coil spring compressor tool or equivalent to the coil spring and compress the coil spring.
3. Install the coil spring and insulator to the lower control arm.
4. Raise the lower control arm into position and place a suitable safety jack under the lower control arm rear leg near the bushing.
5. Install the rear pivot bolt.
6. Install the front pivot bolt.
7. Install the lower control arm pivot bolt retaining nuts and washers. Tighten: Tighten the nuts to 145 N.m (107 lb ft).
8. Remove the OTC 7045-B coil spring compressor tool or equivalent from the coil spring.
9. Lower and remove the safety jacks.
10. Install the front stabilizer shaft link. Refer to «Stabilizer Shaft Replacement»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
11. Install the shock absorber. Refer to «Shock Absorber Replacement (RWD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) or «Shock Absorber Replacement (4WD)»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
12. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
13. Lower the vehicle.

Tools Required

J 43631 Ball Joint Remover

Scheme 12

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the wheel stud from the hub flange using the J 43631 .
4. Remove the wheel stud from the hub flange.

Scheme 13

1. Install the new stud into the hub flange hole using firm hand pressure.
2. Install 4 washers to the new wheel stud.
3. Thread a wheel nut onto the new stud with the flat side facing the front hub flange.
4. Tighten the lug nut until the stud contacts the back of the hub flange.
5. Remove the wheel nut.
6. Remove the washers.
7. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
8. Lower the vehicle.

Scheme 14

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
4. Remove the wheel speed sensor mounting bolt.
5. Remove the wheel speed sensor from the wheel hub and bearing.
6. Remove the wheel hub and bearing mounting bolts.
7. Remove the wheel hub and bearing and splash shield from the steering knuckle.

Scheme 15

1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing.
2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent.
3. Install the wheel hub and bearing and splash shield to the steering knuckle.
4. Install the wheel hub and bearing mounting bolts. Tighten: Tighten the bolts to 180 N.m (133 lb ft).
5. Install the wheel speed sensor to the wheel hub and bearing.
6. Install the wheel speed sensor retaining bolt. Tighten: Tighten the bolt to 18 N.m (13 lb ft).
7. Install the rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical-hydraulic/#disc-brake-system) .
8. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
9. Lower the vehicle.

J 45859 Axle Remover

Scheme 16

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
3. Remove the rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
4. Remove the front axle hub cap.
5. Remove the wheel driveshaft retaining nut and washer from the wheel driveshaft.
6. Using the J 45859 or equivalent, disengage the wheel driveshaft from the hub and bearing.
7. Remove the wheel speed sensor mounting bolt from the wheel hub and bearing.
8. Remove the wheel speed sensor from the wheel hub and bearing.
9. Remove the wheel hub and bearing mounting bolts.
10. Remove the wheel hub and bearing and splash shield from the steering knuckle.

1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing.
2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent.
3. Install the wheel hub and bearing and splash shield to the steering.
4. Install the wheel hub and bearing mounting bolts. Tighten: Tighten the bolts to 180 N.m (133 lb ft).
5. Install the wheel speed sensor to the wheel hub and bearing.
6. Install the wheel speed sensor mounting bolt to the wheel hub and bearing. Tighten: Tighten the sensor mounting bolt to 18 N.m (13 lb ft).
7. Install the wheel driveshaft retaining nut and washer. Tighten: Tighten the nut to 210 N.m (155 lb ft).
8. Install the front axle hub cap.
9. Install the rotor. Refer to «Brake Rotor Replacement - Front»(/chevrolet/chevy-express-g3500/1996-2012/remont/mechanical-hydraulic/#disc-brake-system) in Disc Brakes.
10. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/chevy-express-g3500/1996-2012/remont/wheel-tire-system/#tires-and-wheels__tire-and-wheel-removal-and-installation) in Tires and Wheels.
11. Lower the vehicle.

J 36202 Torsion Bar Unloading/Loading Tool. See Special Tools and Equipment .

Scheme 17

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Install the J 36202 to the adjustment arm and the support. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
3. Increase the tension on the adjustment arm until the load is removed from the adjustment bolt and the adjuster nut.
4. Remove the adjustment bolt and the adjuster nut.
5. Remove the J 36202 , allowing the torsion bar to unload. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
6. Remove the adjustment arm by sliding the torsion bar forward until the torsion bar clears the adjustment arm. Use your hand to support the adjustment arm as the adjustment arm releases from the torsion bar.
7. Remove the torsion bar support bolts.
8. Remove the torsion bar support.
9. Remove the torsion bars from the vehicle.

1. Install the torsion bars to the lower control arm.
2. Install the torsion bar support.
3. Install the torsion bar support bolts. Tighten: Tighten the bolts to 95 N.m (70 lb ft).
4. While supporting the adjustment arm, slide the torsion bar rearward until the torsion bar fully engages the adjustment arm.
5. Install the J 36202 to the adjustment arm and the support. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
6. Increase the tension on the adjustment arm in order to load the torsion bar.
7. Install the adjustment bolt and the adjuster nut.
8. Remove the J 36202 releasing the tension on the torsion bar until the load is taken up by the adjustment bolt. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system) .
9. Lower the vehicle.
10. Measure the Z height. Refer to «Trim Height Inspection Procedure»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#suspension-system-general-diagnosis) in Suspension General Diagnosis.
11. Turn the adjustment bolt clockwise to increase the Z height and counterclockwise to decrease the Z height.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Support the lower control arm with a jack stand.
3. Remove the shock absorber nut and bushing.
4. Remove the shock absorber lower mounting bolts.
5. Remove the shock absorber from the vehicle.

Scheme 18

1. Install the shock absorber to the vehicle.
2. Align the shock absorber with the mounting holes in the lower control arm.
3. Install the shock absorber lower mounting bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the shock absorber upper retaining nut and bushing. Tighten: Tighten the nut to 20 N.m (15 lb ft).
5. Remove the safety stands.
6. Lower the vehicle.
7. Dispose of the shock absorber. Refer to «Shock Absorber Disposal»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system__shock-absorber-disposal) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g3500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Support the lower control arm with a jack stand.
3. Remove the shock absorber upper retaining nut and bushing.
4. Remove the shock absorber lower mounting bolt.
5. Remove the shock absorber.

1. Install the shock absorber. Insert the stem through the hole in the shock tower.
2. Align the shock absorber with the mounting holes in the lower control arm.
3. Install the shock absorber lower mounting bolt and nut. Tighten: Tighten the nut to 80 N.m (59 lb ft).
4. Install the shock absorber upper retaining nut and bushing. Tighten: Tighten the nut to 20 N.m (15 lb ft).
5. Remove the safety stands.
6. Lower the vehicle.
7. Dispose of the shock absorber. Refer to «Shock Absorber Disposal»(/chevrolet/chevy-express-g3500/1996-2012/remont/suspension-front/#front-suspension-system__shock-absorber-disposal) .

Shock Absorber Disposal

1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch.
2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended.
3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil.
4. Make an indentation in the middle (2) of the tube (3) with a centerpunch.
5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping oil.
6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock absorber.

General Description (Coil Spring)

The front suspension has 2 primary purposes

1. Isolate the driver from irregularities in the road surface.
2. Define the ride and handling characteristics of the vehicle.

The front suspension absorbs the impact of the tires travelling over irregular road surfaces and dissipates this energy throughout the suspension system. This process isolates the vehicle occupants from the road surface. The rate at which the suspension dissipates the energy and the amount of energy that is absorbed is how the suspension defines the vehicle's ride characteristics. Ride characteristics are designed into the suspension system and are not adjustable. The ride characteristics are mentioned in this description in order to aid in the understanding of the functions of the suspension system. The suspension system must allow for the vertical movement of the tire and wheel assembly as the vehicle travels over irregular road surfaces while maintaining the tire's horizontal relationship to the road.

This requires that the steering knuckle be suspended between an upper and a lower control arm. The lower control arm attaches from the steering Knuckle at the outermost point of the control arm. The attachment is through a ball and socket type joint. The innermost end of the control arm attached at 2 points to the vehicle frame, through semi-rigid bushings. The upper control arm attaches to the frame in the same fashion. Between the lower control arm and a spring seat on the vehicle's frame, under tension, is a coil spring.

This up and down motion of the steering knuckle as the vehicle travels over bumps is absorbed predominantly by the coil spring. The vertical movement of the steering knuckle as the vehicle travels over irregular road surfaces will tend to compress the spring and spring tension will lead the spring to return to the original, at-rest state. This action isolates the vehicle from the road surface. The upper and lower control arms are allowed to pivot at the vehicle frame in a vertical fashion. The ball joint allows the steering knuckle to maintain the perpendicular relationship to the road surface.

A shock absorber is used in conjunction with this system in order to dampen out the oscillations of the coil spring. A shock absorber is a basic hydraulic cylinder. The shock is filled with oil and has a moveable shaft that connects to a piston inside the shock absorber. Valves inside the shock absorber offer resistance to oil flow and consequently inhibit rapid movement of the piston and shaft. Each end of the shock absorber is connected in such a fashion to utilize this recoil action of a spring alone.

Front suspensions systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right lower control arm assemblies through the stabilizer link and stabilizer shaft insulators. This bar controls the amount of independent movement of the suspension when the vehicle turns. Limiting the independent movement defines the vehicle's handling characteristics on turns.

General Description (Torsion Bar)

The front suspension has 2 primary purposes

1. Isolate the driver from irregularities in the road surface.
2. Define the ride and handling characteristics of the vehicle.

The front suspension absorbs the impact of the tires travelling over irregular road surfaces and dissipates this energy throughout the suspension system. This process isolates the vehicle occupants from the road surface. The rate at which the suspension dissipates the energy and the amount of energy that is absorbed is how the suspension defines the vehicle's ride characteristics. Ride characteristics are designed into the suspension system and are not adjustable. The ride characteristics are mentioned in this description in order to aid in the understanding of the functions of the suspension system. The suspension system must allow for the vertical movement of the tire and wheel assembly as the vehicle travels over irregular road surfaces while maintaining the tire's horizontal relationship to the road.

This requires that the steering knuckle be suspended between an upper and a lower control arm. The lower control arm attaches from the steering knuckle at the outermost point of the control arm. The attachment is through a ball and socket type joint. The innermost end of the control arm is attached at 2 points to the vehicle frame through semi-rigid bushings. The upper control arm attaches to the frame in the same fashion. Attached to the lower control arm is a torsion bar. Torsion bars are steel or steel composite shaft that connects from the lower control arm an adjustable mount at the torsion bar crossmember. The torsion bar functions as a spring in this suspension system. The torsion bar absorbs energy from irregular road surfaces by twisting force along the center axis. The torsion bar has a resistance to this twisting motion and will return to the original, at-rest position similar to that of a spring.

A shock absorber is used in conjunction with this system in order to dampen out the oscillations of the torsion bar. A shock absorber is a basic hydraulic cylinder. The shock is filled with oil and has a moveable shaft that connects to a piston inside the shock absorber. Valves inside the shock absorber offer resistance to oil flow and consequently offer resistance to rapid movement of the piston and shaft. Each end of the shock absorber is connected in such a fashion in order to utilize this recoil action of a torsion bar alone.

Front suspension systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right lower control arm assemblies through the stabilizer link and stabilizer shaft insulators. This bar controls the amount of independent movement of the suspension when the vehicle turns. Limiting the independent movement defines the vehicle's handling characteristics on turns.

Special Tools

Special Tools Illustration Tool Number/Description J 24319-B Steering Linkage and Tie Rod Puller J 36202 Torsion Bar Loading/Unloading Tool J 43631 Ball Joint Remover J 45851 Ball Joint Separator Protector Adapters J 45859 Axle Remover

Scheme 19

Scheme 20

Scheme 21

Scheme 22

See also:
• Lifting and Jacking the Vehicle
• Tire and Wheel Removal and Installation
• Measuring Wheel Alignment
• Fastener Notice
• Wheel Drive Shaft Replacement
• Brake Rotor Replacement - Front
• Trim Height Inspection Procedure
• Stabilizer Shaft Link Replacement
• Lower Control Arm Replacement (RWD)
• Lower Control Arm Replacement (4WD)
• Shock Absorber Disposal