OEM 2009 Chevrolet Express 2500 Oil Pan

2009 Chevrolet Express 2500 Oil Pan Parts Questions & Experts Answers

• Q: How to replace the oil pan on 2009 Chevrolet Express 2500?

  A: The first thing one will do to replace the Oil Pan is-first, if the machine is equipped with all-wheel drive (AWD), one should remove the inner axle housing nuts and washers attached to the bracket, and afterward, one should support the engine's front drive axle with a suitable jack. Next, remove the differential carrier low and high mounting bolts and nuts and lower the front drive axle and remove the transmission cover bolt and crossbar bolts before removing the crossbar. Then, the transmission cover bolt and cover need to be removed, drain the engine oil, remove the engine Oil Filter, and reinstall the drain plug and Oil Filter until tight. For cars equipped with the 4l60-e automatic transmission, pull off the side transmission bolt and stud on the right, and the bottom bolt on the left side; for those with the 4l-80e automatic gear, either equip yourself with a gear wrench that allows you to loose the transmission converter cover bolts or forcefully remove them by turning them in a opposite direction. Remove electrical connector of the oil level sensor, and battery cable channel bolt, slide the channel pin out of the Oil Pan tab, and remove the positive battery cable clip bolt. Move to take out the Oil Pan bolts and the Oil Pan to avoid foreign material getting into the oil passages. If needed, drill out the Oil Pan Gasket retaining rivets and then remove the gasket and discard the gasket and rivets. Check and clean the engine Oil Pan as long as necessary. For installation, run a 5 mm (0.20 in) bead of sealant 20 mm (0.80 in) long to the engine block directly onto the tabs of front and rear cover gaskets that extend into the Oil Pan surface ensuring alignment of oil gallery passages. Put together the Oil Pan Gasket to the pan and bolt the Oil Pan to the block including the gasket, and bolt until snug without over-tightening the bolts. With a 4l80-e automatic transmission, install the transmission converter cover bolts until they are tight; for the 4l60-e automatic transmission, connect the transmission bolt to the right hand side to the required tightness and then the bottom bolt to the left side. Tighten the Oil Pan-to-front cover bolts to 25 nm (18 lb ft) and Oil Pan-to-rear to 12 nm (106 lb in) also the converter cover-to-transmission bolts/stud to 50 nm (37 lb ft). Install the positive battery cable clip bolt and tighten to 9 nm(80 lb in), slide the channel pin into the Oil Pan tab while installing the battery cable channel bolt and tighten it to 12 nm(106 lb in). Connect the oil level sensor electrical connector, the transmission cover, and bolt it to 12 nm (106 lb in), further installing the crossbar, which also requires 100 nm (74 lb ft) to bolt), and finally the transmission cover with 12 nm (106 lb in). Drive the front axle up into its position, secure the differential carrier upper mounting bolt and nut just tight, tighten the differential carrier mounting bolt and nut at the lower mounting of the inner axle housing to the bracket to 100 nm (75 lb ft), and secure the inner axle housing washers and nuts to the bracket to 100 nm (75 lb ft). Lastly, remove the jack from the front drive axle, and install new engine oil and a new Oil Filter.