Express, Savana, G1500, G2500, G3500, 1998-2005

Coil Springs

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Removal & Installation



  1. Support the vehicle safely under the frame rails. The control arms should hang freely.
  2.  
  3. Remove or disconnect the following:

    Wheel
     
    Shock absorber lower end mounting nut/bolt
     
    Stabilizer bar from the lower control arm
     

  4.  
  5. Support the lower control arm and install a spring compressor on the spring or chain the spring to the control arm as a safety precaution.
    NOTE
    If equipped with an air cylinder inside the spring, remove the valve core from the cylinder and expel the air by compressing the cylinder with a prybar. With the cylinder compressed, replace the valve core so the cylinder will stay in the compressed position. Push the cylinder as far as possible towards the top of the spring.

  6.  
  7. Raise the front end to remove the tension from the lower control arm the bolts securing the control arm.
    NOTE
    The cross-shaft and lower control arm keeps the coil spring compressed. Use care when lowering the assembly.

  8.  
  9. Slowly lower the control arm until the spring can be removed. Be sure all compression is relieved from the spring.
  10.  
  11. If the coil spring was chained, remove the chain and spring. If a compressor was used, remove the spring and slowly release the compressor.
  12.  
  13. Remove the air cylinder, if equipped.
  14.  

To install:

  1. Install or connect the following:

    Air cylinder so the protector plate is toward the upper control arm. The Schrader valve should protrude through the hole in the lower control arm.
     
    Chain and spring or compress the spring and install the assembly
     

  2.  
  3. Slowly raise the control arm.

    Bolts securing the control arm. Tighten to 107 ft. lbs. (145 Nm).
     
    Stabilizer bar to the lower control arm. Torque the nuts to 24 ft. lbs. (34 Nm).
     
    Shock absorber at the lower end. Torque the nuts to 37 ft. lbs. (50 Nm).
     
    Air cylinders, inflate the cylinder to 60 psi (414 kpa) if equipped
     
    Wheel
     

  4.  
  5. Once the weight of the vehicle is on the wheels, reduce the air cylinder pressure to 50 psi.
  6.  

  1. Raise and support the vehicle.
  2.  
  3. Remove or disconnect the following:

    Engine protection shield
     
    Frame cross bar (2500 series only)
     
    Tire and wheel assembly
     
    Shock absorber
     
    Front stabilizer shaft link
     

  4.  
  5. Install tool J23028-15 using the outboard locating tab (1500 Series), or, the inboard locating tab (2500 Series).

    Click image to see an enlarged view

    Fig. Position the coil spring so the bottom end of the spring covers only one drain hole-the other hole must remain open



    Click image to see an enlarged view

    Fig. Installing tool J23028

  6.  
  7. Attach the retaining hook to the control arm. Tighten the wing nut until free-play is eliminated.

    Click image to see an enlarged view

    Fig. Retaining hook installation



    Click image to see an enlarged view

    Fig. Tool attached to a jack

  8.  
  9. Securely attach tool J23028-01 to a suitable transmission jack. Raise the jack until the yokes of tool J23028-01 line up with the notches in J23028-15.
  10.  
  11. Using the tools and the transmission jack, relieve the spring tension from the lower control arm pivot bolts.
  12.  
  13. Remove or disconnect the following:

    Lower control arm pivot bolt nuts
     
    Rear pivot bolt
     
    Front pivot bolt

    Click image to see an enlarged view

    Fig. Lower control arm removal

     

  14.  
  15. Slowly lower the transmission jack in order to unload the front coil spring. It may be necessary to use a pry bar in order to guide the lower control arm out of position.
  16.  
  17. Remove the coil spring and the insulator.
  18.  

To install:

  1. Install the coil spring and the insulator to the lower control arm.
  2.  
  3. Raise the transmission jack in order to compress the front coil spring. It may be necessary to use a pry bar in order to guide the lower control arm into position.
  4.  
  5. Install or connect the following:

    Front pivot bolt
     
    Rear pivot bolt
     
    Lower control arm pivot nuts. Tighten the pivot bolt nuts to 107 ft. lbs. (145 Nm).
     

  6.  
  7. Lower the jack. Remove the tool from the control arm.

    Front stabilizer shaft link
     
    Shock absorber
     
    Tire and wheel assembly
     
    Frame cross bar (2500 series only). Tighten the nuts to 74 ft. lbs. (100 Nm).
     

  8.  
  9. Install the engine protection shield.
  10.  
  11. Remove the safety stands. Lower the vehicle.
  12.  

 
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