Chevrolet Express 2500 Parts

Chevrolet Express 2500 Parts Questions & Answers

• Alternator
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  Q: How to replace the alternator on Chevrolet Express 2500?

  A: Firstly separate the upper Fan Shroud before replacing the auxiliary generator. Start by removing the Drive Belt. Begin the process by disconnecting the auxiliary generator electrical connector followed by the positive cable procedure that includes boot slide-down and positive cable nut removal and cable removal sequence. You must first remove the auxiliary generator by removing all three mounting bolts. Position the new auxiliary generator into place before tightening the three bolts to 50 nm (37 lb ft) torque. Reconnect the positive cable by placing it correctly followed by tightening the positive cable nut to 10 nm (89 lb in). Replace the boot over the terminal stud afterward. Complete generator wiring after hooking up the electrical connector before fitting the Drive Belt and replacing the upper shroud.
• Emblem, Front
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  Q: How to replace the front side door emblem/nameplate on Chevrolet Express 2500?

  A: The first thing to do for replacing the front side door emblem/nameplate is to put tape around the space, making it easier to keep the emblem lined up. Set the heat gun (J 25070) 6.0 inches away from the surface and move it in circles around the emblem/nameplate for half a minute. Make sure to use a plastic, flat-bladed tool to remove the emblem/nameplate and keep the paint safe. Once you've removed the emblem/nameplate, go over the door panel surface and its back with 3M(TM) Scotch Brite Molding Adhesive Remover Disk (3M(TM) P/N If the emblem/nameplate location is not labeled, use tape to help you align it. Heat the door panel again using the heat gun (J 25070) until it's a minimum of 21°C (70°F), making sure the glue side of the emblem/nameplate stays cool. Take off the backing from the front end of the emblem/nameplate and stick it to the door panel surface as you keep taking off the rest of the backing. Hand roll the emblem/nameplate to ensure it sticks well and look at it to see if it is bonded before removing the tape from around the door emblem.
• Distributor Assembly
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  Q: How to replace the distributor in an engine on Chevrolet Express 2500?

  A: Before changing the Distributor make sure to turn off the ignition, remove engine cover, air cleaner assembly and air intake resonator assembly. Compare the rotor's position with the cylinder it belongs to using the heater and the vacuum pipe connection. Disconnect the Spark Plug Wires from the Distributor Cap as follows: twist each wire boot 1/2 turn and simply pull on the boot. The electrical connection at the base of the Distributor is next to be pulled out, also, the 2 screws holding the Distributor Cap in place are to be removed and thrown away. Disconnect the Distributor Cap and use the grease pencil to mark the position of rotor with reference to the housing of Distributor and also the Intake Manifold of Distributor's. While you are pulling the Distributor out, observe that the rotor will rotate counter-clockwise about 42 degrees and put a mark number 2 on the base of the Distributor for realignment when installing. Your next step is to remove the mounting clamp hold-down bolt; pull out the Distributor. For installation procedure 1: using a new Distributor assembly, put 2 marks in the new housing at the same place as the original. Align rustor to the second mark , guide the Distributor on the engine, and bring the hole at hold down base on the engine cover hole at the Intake Manifold. As you install, the rotor will turn clockwise 42 degrees. Ensure the rotor segment is aligned with mark on the Distributor base. If there is a misalignment, remove and re-mount the Distributor. If you see any oil spill in the oil filler valve tube, feel free to replace that tube as well. Tighten the Distributor mounting clamp bolt to 25 n.m (18 lb ft) and fit the Distributor Cap while fitting the Distributor Cap screws that are new that need to be tightened to 2.4 n.m (21 lb in). Reconnect the electrical connector, reinstall the Spark Plug Wires and ignition coil wire making sure all are initially correct. Following the installation, if the malfunction indicator lamp lights up with a value of dtc p1345, the Distributor has been installed incorrectly. For installation method 2, turn the crankshaft balancer in a clockwise direction so that the alignment marks fall on the engine front cover tabs so that the number 1 Piston is at tdc of the compression stroke. Assemble the bottom stem of the Distributor with the white paint mark aligned with the pre-drilled indent hole in the gear with the make note of the rotor segment aligning as shown for a v6 engine. Using a long screwdriver, align the oil pump drive shaft with the Distributor's drive tab and guide the latter into the engine with the flat part in the direction of the car's front; the rotor segment must be aligned with the Distributor's pointer on the base of the latter. Make sure the Distributor mounting bolt is tightened to 25 n.m (18 lb ft) and fit the Distributor Cap then tighten new screws to 2.4 n.m (21 lb in), reconnect the electrical connector and plug in the spark plug and ignition coil wire making sure that it is in the correct orientation. Repeat installation procedure 2 should the malfunction indicator lamp light up following installation signifying a wrong installation. Finally, install the engine cover.
• Axle Seal, Front Inner
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  Q: How to replace the Front Drive Axle Inner Wheel Seal and Inner Shaft Bearing on Chevrolet Express 2500?

  A: The first step to replace the Front Drive Axle Inner Shaft Seal and Inner Shaft Bearing requires lifting the vehicle while draining the differential carrier assembly fluid. The left side seal replacement requires disconnecting the wheel drive shaft from its inner shaft flange followed by taking off the inner shaft before removing the inner shaft seal cover bolts and assembly. The process to replace the left side bearing requires removal of the differential carrier assembly together with the left inner shaft and inner shaft seal cover bolts and assembly. Apply the J 29369-1 (Bushing and Bearing Remover) to the inner shaft bearing on its backside before connecting the J 2619-01 (Slide Hammer) for pulling out the inner shaft bearing. First remove the inner shaft from the housing after taking out the inner shaft and housing assembly to reach both the right side seal and bearing. Secure the inner shaft housing within a vise while applying the J 29369-1 (Bushing and Bearing Remover) to its back surface followed by attaching the J 2619-01 (Slide Hammer) to pull out the seal or seal along with bearing. Installation of right side bearings requires using the vise to secure the inner shaft housing prior to bearing installation through J 42211 (Axle Bearing Installer) and J 8092 (Universal Driver Handle - 3/4 in - 10). When installing the right side seal use J 42738 (Seal Installer) while carefully guiding the inner shaft through the oil seal. Put the inner shaft inside the housing before reuniting the components of the inner shaft and housing assembly. The owners must use J 42211 (Axle Bearing Installer) along with J 8092 (Universal Driver Handle - 3/4 in - 10) to install the left side bearing while they should also install the inner shaft seal cover assembly followed by securing the cover bolts at 18 Nm (13 lb ft) and guiding the left inner shaft through the oil seal until it contacts the differential case side gear. Use a soft-faced mallet while tapping the retaining ring into its groove until it reaches full seating then obstruct it with a finger to check its locking position. Reinstall the differential carrier assembly to the inner shaft flange as well as the wheel drive shaft and then add the suitable fluid to the differential carrier assembly before lowering the vehicle.