Frame and Underbody: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Support the engine. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
3. Remove the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
4. Remove the front fender liner enough to gain access to the front frame bolts. Refer to «Wheelhouse Liner Replacement - Front»(ref-241699-S18568318592006081100000) in Exterior Trim.
5. Remove both outer tie rod ends from the steering knuckles. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) in Front Suspension.
6. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement (FWD)»(ref-241710-S13642053022006081100000) or «Stabilizer Shaft Replacement (AWD)»(ref-241710-S00902690242006081100000) in Front Suspension.
7. Remove the propeller shaft, if equipped with all wheel drive (AWD). Refer to «Propeller Shaft Replacement»(ref-241711-S04499692822006081100000) in Propeller Shaft.
8. Remove the catalytic converter pipe, if equipped with AWD. Refer to «CATALYTIC CONVERTER HEAT SHIELD REPLACEMENT»(ref-241745-S12952982712006081100000) in Engine Exhaust.
9. Remove the power steering gear heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) in Power Steering System.
10. Remove the power steering gear bolts. Refer to «Power Steering Gear Replacement»(ref-241712-S39953065112006081100000) in Power Steering System.
11. Remove the power steering gear from the frame. Refer to «Power Steering Gear Replacement»(ref-241712-S39953065112006081100000) in Power Steering System.
12. Use mechanics wire secure the power steering gear to the exhaust pipe.
13. Remove the front engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
14. Remove the power steering cooler pipe from the frame. Refer to «Power Steering Cooler Pipe/Hose Replacement»(ref-241712-S22419227572006081100000) in Power Steering System.
15. Use mechanics wire to secure the power steering cooler line out of the way.
16. Disconnect the front wheel speed sensor connectors.
17. Remove the front wheel speed sensor wiring harnesses from the lower control arms.
18. Remove the lower ball joints from the steering knuckles. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) in Front Suspension.
19. Remove the engine mount nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) in Engine Mechanical - 3.5L.
20. Remove the transaxle mount nuts. Refer to «Automatic Transmission Mount Replacement»(ref-241713-S11891386862006081100000) in Automatic Transaxle - 4T65-E.
21. Lower the vehicle until the frame contacts the J 39580 . See «Special Tools»(ref-241708-S00567791482006081100000) .
22. Remove the frame front bolts (2).
23. Remove the frame rear bolts (4).
24. Remove the frame strap bolts (3) and straps (5).
25. Raise the vehicle in order to separate the frame from the vehicle.
26. If you are replacing the frame, perform the following steps: Remove the frame insulators from the frame. Refer to «Frame Cushion or Insulator Replacement - Front»(ref-241708-S32573411602006081100000) . Remove the lower control arms from the frame. Refer to «Lower Control Arm Replacement»(ref-241710-S06348524922006081100000) in Front Suspension.

Installation Procedure

1. If you are replacing the frame, perform the following steps: Install the lower control arms to the frame. Refer to «Lower Control Arm Replacement»(ref-241710-S06348524922006081100000) in Front Suspension. Install the frame insulators to the frame. Refer to «Frame Cushion or Insulator Replacement - Front»(ref-241708-S32573411602006081100000) .
2. Position the transaxle table with the frame under the vehicle.
3. Lower the vehicle until the frame is close to the vehicle.
4. Adjust the utility straps as necessary in order to align the powertrain mounts with the frame.
5. Inserting two 19 mm (0.75 in) diameter X 203 mm (8.0 in) long guide pins or drill bits into the frame right side alignment holes in order to align the frame.
6. Install the frame front bolts (2). Tighten: Tighten the bolts to 130 N.m (96 lb ft).
7. Install the frame straps (5) and bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
8. Install the frame rear bolts (4). Tighten: Tighten the bolts to 240 N.m (177 lb ft).
9. Remove the alignment pins from the frame.
10. Install the transaxle mount nuts. Refer to «Automatic Transmission Mount Replacement»(ref-241713-S11891386862006081100000) in Automatic Transaxle - 4T65-E.
11. Install the engine mount nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) in Engine Mechanical - 3.5L.
12. Install the wheel speed sensor wiring harnesses to the lower control arms.
13. Connect the wheel speed sensor electrical connectors.
14. Install the lower ball joints to the steering knuckles. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) in Front Suspension.
15. Install the power steering cooler pipe to the frame. Refer to «Power Steering Cooler Pipe/Hose Replacement»(ref-241712-S22419227572006081100000) in Power Steering System.
16. Install the front engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
17. Install the power steering gear to the frame. Refer to «Power Steering Gear Replacement»(ref-241712-S39953065112006081100000) in Power Steering System.
18. Install the power steering gear bolts. Refer to «Power Steering Gear Replacement»(ref-241712-S39953065112006081100000) in Power Steering System.
19. Install the power steering gear heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) in Power Steering System.
20. Install the propeller shaft, if equipped with AWD. Refer to «Propeller Shaft Replacement»(ref-241711-S04499692822006081100000) in Propeller Shaft.
21. Install the catalytic converter pipe, if equipped with AWD. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-237186-S34493320012006071400000) in Engine Exhaust.
22. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement (FWD)»(ref-241710-S13642053022006081100000) or «Stabilizer Shaft Replacement (AWD)»(ref-241710-S00902690242006081100000) in Front Suspension.
23. Install both tie rod ends to the steering knuckles. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) in Front Suspension.
24. Install the front fender liner. Refer to «Wheelhouse Liner Replacement - Front»(ref-241699-S18568318592006081100000) in Exterior Trim.
25. Install the front tires and wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
26. Lower the vehicle.
27. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L.
28. Inspect the front wheel alignment and adjust the toe angle if necessary. Refer to «Measuring Wheel Alignment»(ref-241714-S28247978332006081100000) in Wheel Alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the rear tires and the wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
3. Support rear differential carrier using a utility stand.
4. Remove the rear differential carrier mounting bolts (5) from the rear crossmember. Refer to «Differential Replacement»(ref-241715-S16935702622006081100000) in Rear Drive Axle.
5. Remove the rear suspension knuckle. Refer to «Knuckle Replacement»(ref-241716-S36183170482006081100000) in Rear Suspension.
6. Disconnect the wheel speed sensor harness from the lower control arm and from the rear cross member.
7. Remove the rivets that attach the park brake cable to the rear crossmember.
8. Remove the automatic level control (ALC) height sensor and link from the crossmember bar and lower control arm. Refer to «Automatic Level Control Sensor Replacement»(ref-241717-S12966922802006081100000) in Automatic Level Control.
9. Secure the ALC wiring harness out of the way.
10. Using a utility jack, support the rear crossmember.
11. Remove the rear crossmember mounting bolts.
12. Lower the rear crossmember.
13. Remove the rear stabilizer shaft. Refer to «Stabilizer Shaft Replacement»(ref-241716-S28904432162006081100000) in Rear Suspension.
14. Remove the rear axle upper control arms from the rear crossmember. Refer to «Rear Axle Upper Control Arm Replacement»(ref-241716-S08863955762006081100000) in Rear Suspension.
15. Remove the rear axle lower control arms from the rear crossmember. Refer to «Rear Axle Lower Control Arm Replacement»(ref-241716-S08140625032006081100000) in Rear Suspension.
16. Remove the tie rods from the rear crossmember. Refer to «Tie Rod Replacement (Front Wheel Drive)»(ref-241716-S13789051492006081100000) or «Tie Rod Replacement (All Wheel Drive)»(ref-241716-S23168460372006081100000) in Rear Suspension.

1. Install the tie rods to the crossmember. Refer to «Tie Rod Replacement (Front Wheel Drive)»(ref-241716-S13789051492006081100000) or «Tie Rod Replacement (All Wheel Drive)»(ref-241716-S23168460372006081100000) in Rear Suspension.
2. Install the rear axle lower control arms onto the rear crossmember. Refer to «Rear Axle Lower Control Arm Replacement»(ref-241716-S08140625032006081100000) in Rear Suspension.
3. Install the rear axle upper control arms onto the rear crossmember. Refer to «Rear Axle Upper Control Arm Replacement»(ref-241716-S08863955762006081100000) in Rear Suspension.
4. Install the rear stabilizer shaft onto the rear crossmember. Refer to «Stabilizer Shaft Replacement»(ref-241716-S28904432162006081100000) in Rear Suspension.
5. Raise the rear crossmember.
6. Align the rear crossmember using guide pins through the rail holes (1).
7. Install the rear crossmember mounting bolts.
8. Tighten the mounting bolts. Tighten: Tighten the rear crossmember mounting bolts to 130 N.m (96 lb ft).
9. Install the ALC height sensor onto the crossmember and lower control arm. Refer to «Automatic Level Control Sensor Replacement»(ref-241717-S12966922802006081100000) in Automatic Level Control.
10. Install the rear differential carrier mounting bolts (5). Refer to «Differential Replacement»(ref-241715-S16935702622006081100000) in Rear Drive Axle.
11. Attach the parking brake cable onto the rear crossmember. Refer to «Park Brake Cable Replacement - Left Rear»(ref-241718-S09706043682006081100000) and «Park Brake Cable Replacement - Right Rear»(ref-241718-S06488153662006081100000) in Park Brake.
12. Connect the wheel speed sensor harness onto the rear crossmember and the lower control arm.
13. Install the rear suspension knuckle. Refer to «Knuckle Replacement»(ref-241716-S36183170482006081100000) in Rear Suspension.
14. Install the rear tires and the wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
15. Lower the vehicle.
16. Inspect for rear wheel alignment and adjust as necessary. Refer to «Measuring Wheel Alignment»(ref-241714-S28247978332006081100000) in Wheel Alignment.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
2. Disconnect the steering intermediate shaft. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) .
3. Install a jackstand under the center of the frame, between the front frame insulators.
4. Remove the front frame bolts and retainers.
5. Lower the front of the frame.
6. Remove the frame front upper insulators.
7. Install the J 45296 to the front frame insulator you are removing. See «Special Tools»(ref-241708-S00567791482006081100000) .
8. Using J 45296 , remove the front frame insulator from the frame. See «Special Tools»(ref-241708-S00567791482006081100000) .

1. Clean the front frame insulator opening.
2. Apply a thin coat of rubber lubricant GM P/N 1051717 (Canadian P/N 5728223) or equivalent to the inside of the front frame insulator opening.
3. Apply a thin coat of rubber lubricant GM P/N 1051717 (Canadian P/N 5728223) or equivalent to the front frame insulator.
4. Align the front frame insulator to the front frame opening with the front frame alignment tabs facing to the front.
5. Using J 45296 , install the front frame insulator to the front frame. See «Special Tools»(ref-241708-S00567791482006081100000) .
6. Install the frame front upper insulators.
7. Raise the front of the frame.
8. Install the front frame bolts and retainers. Tighten: Tighten the bolts to 130 N.m (96 lb ft).
9. Remove the jackstand.
10. Connect the steering intermediate shaft. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) .
11. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the intermediate shaft from the steering gear stub shaft. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
3. Install a utility stand to the rear of the frame.
4. Remove the frame bolts (4).
5. Remove the frame strap bolts (3) and straps (5).
6. Lower the rear of the frame.
7. Remove the upper (1) and lower insulators (2) from the rear of the frame as a set.

1. Apply a thin coat of rubber lubricant GM P/N 1051717 (Canadian P/N 5728223), to the inside surface of the lower insulator and to the top surface of the upper insulator.
2. Install the upper (1) and lower insulators (2) to the rear of the frame as a set.
3. Raise the rear of the frame.
4. Install the frame straps (5) and bolts (3). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the rear frame bolts (4). Tighten: Tighten the bolts to 240 N.m (177 lb ft).
6. Raise the vehicle and secure.
7. Remove the utility stand.
8. Install the intermediate shaft to the steering gear stub shaft. Refer to «Intermediate Steering Shaft Replacement»(ref-241676-S06460356582006081100000) in Steering Wheel and Column.
9. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the rubber grommet from the rear exhaust hanger.
3. Lower the automatic level control compressor assembly. Refer to «Automatic Level Control Air Compressor Air Filter Replacement»(ref-241717-S19239575202006081100000) in Automatic Level Control.
4. Remove the trailer hitch assembly from the vehicle.

1. Install the trailer hitch onto the vehicle. Tighten: Tighten all 0.5 in diameter carriage bolts to 101 N.m (75 lb ft) Tighten all M10 bolts to 54 N.m (40 lb ft).
2. Install the automatic level control compressor assembly onto the vehicle. Refer to «Automatic Level Control Air Compressor Air Filter Replacement»(ref-241717-S19239575202006081100000) in Automatic Level Control.
3. Install the rubber grommet onto the rear exhaust hanger.
4. Lower the vehicle.

1. Disconnect the negative battery cable. Refer to «ENGINE ELECTRICAL»(ref-241706) .
2. Remove the carpet from the trunk area. Refer to «Carpet Replacement»(ref-241679-S14083918952006081100000) in Interior Trim.
3. Remove the following components as needed: The sealers The sound deadening materials The corrosion materials
4. Remove the rear suspension support bolt.
5. Place a center punch through the damaged rear suspension support nut. Strike the center punch using a hammer. The punch will leave a dimple on the floor. Use the dimple in order to locate the area where the frame crossmember nut will be removed.
6. Use a cutoff wheel in order to cut an access panel.
7. Lift the panel upward in order to gain access to the frame crossmember nut retainer.
8. Use an air chisel in order to break away the spot welds (1) on one side of the frame crossmember nut retainer (3).
9. Lift one side of the frame crossmember nut retainer enough in order to remove the frame crossmember nut.
10. Remove the rear suspension support nut (2).

1. Install the rear suspension support nut (2).
2. Lower the frame crossmember nut retainer into place. Ensure that the following conditions exist: The frame crossmember nut is correctly positioned. The frame crossmember nut operates correctly.
3. Spot weld the frame crossmember nut retainer in the original location.
4. Clean and prepare the welded surfaces.
5. Apply corrosion protection. Refer to «Anti-Corrosion Treatment and Repair»(ref-241698-S18229512472006081100000) in Paints and Coatings.
6. Install the new rear suspension support bolt to the frame crossmember nut. Tighten: Tighten the bolt to 130 N.m (96 lb ft).
7. Reposition the panel downward to the original position.
8. Stitch weld the panel back to the original position using 25 mm (0.98 in) welds along the seam. Leave 25 mm (0.98 in) gaps between the welds. A solid joint with minimal heat distortion will result. Continue to finish the stitch weld procedure.
9. Use a small grinder in order to remove the excess material from the floor panel until the following conditions exist: The floor panel is smooth. The floor panel is free from rough edges.
10. Clean and prepare the welded surfaces.
11. Apply corrosion protection. Refer to «ANTI-CORROSION MATERIALS NOTICE»(ref-241680-S27438489942006081100000) in General Information.
12. Apply Primer and let the primer dry for approximately 30 minutes. Then apply Dominion Sure Seal P/N 110900 Sound Deadener or the equivalent to the repair area.
13. Install the carpet and the pad over the repair area Refer to «Carpet Replacement»(ref-241679-S14083918952006081100000) in Interior Trim.
14. Apply anti-corrosion compound GM P/N 12346225 or equivalent. Thoroughly coat the inside of the repair area through the access hole.
15. Connect the negative battery cable. Refer to «ENGINE ELECTRICAL»(ref-241706) .