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

Leaf Springs

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise the vehicle and support it so that there is no tension on the leaf spring assembly.
  4.  
  5. Remove or disconnect the following:

    U-bolt nuts, plates, and spacer(s)
     
    Anchor plate
     
    Spring-to-shackle retaining bolts. (Do not remove these bolts)
     
    Bolts which attach the shackle to the rear bracket
     
    Bolt which attaches the spring to the front bracket
     
    Spring from the vehicle
     

  6.  
  7. Inspect the spring and replace any damaged components.
  8.  

To install:


NOTE
If the spring bushings are defective, use the following procedures for replacement. On bushings that are staked in place, the stakes must first be straightened. Using a press or vise, remove the bushing and install the new one. When a new, previously staked bushing is installed, stake it in 3 equally spaced locations.

  1. Place the spring assembly onto the axle housing. Position the front and rear of the spring at the brackets. Raise the axle with a floor jack as necessary to make the alignments.
  2.  
  3. Install or connect the following:

    Front and rear brackets bolts loosely
     
    Spacers and spring plate
     
    New u-bolts, washers and nuts
     
    Anchor plate
     
    U-bolt nuts. Torque them in a diagonal sequence, to 17 ft. lbs. (23 Nm) When the spring is evenly seated, tighten the nuts to 81 ft. lbs. (110 Nm)
     
    Hanger and shackle bolts are properly installed. All bolt heads should be inboard. Don't tighten them yet.
     

  4.  
  5. Using the floor jack, raise the axle until the distance between the bottom of the rebound bumper and its contact point on the axle is 182mm plus or minus 6mm.


  6.  
  7. When the spring is properly positioned, tighten all the hanger and shackle nuts to 70 ft. lbs. (95 Nm)

    Leaf spring-to-shackle nuts 15/25/35 series: 70 ft. lbs. (95 Nm).
     
    Leaf spring-to-shackle nuts C3HD series: 157 ft. lbs. (213 Nm).
     
    Shackle-to-bracket nuts C3HD series: 157 ft. lbs. (213 Nm).
     

  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Support the rear axle independently in order to relieve the tension on the leaf springs.
  6.  
  7. Remove or disconnect the following:

    Real Time Damping (RTD) sensors, if equipped
     
    Trailer hitch if equipped
     
    Fuel tank for left side applications
     
    U-bolt nuts and U-bolts
     
    Spring spacer and anchor plate
     
    Shackle to the frame bracket nut and the bolt
     
    Front spring bracket bolt
     
    Leaf spring assembly from the vehicle
     
    Shackle from the spring

    Click image to see an enlarged view

    Fig. Rear leaf spring front shackle



    Click image to see an enlarged view

    Fig. Rear leaf spring rear shackle

     

  8.  

To install:

  1. Loosely assemble the spring shackle bracket to the frame. Install the shackle bolt. Install the shackle nut.
  2.  
  3. Install the leaf spring assembly to the vehicle.
  4.  
  5. Loosely assemble the spring to the front hanger bracket.
  6.  
  7. Install or connect the following:
    NOTE
    Do not reuse the U-bolts.



    Front spring hanger bracket bolt
     
    Front spring hanger bracket nut
     
    Shackle to the spring bolt
     
    Shackle to the spring nut
     



    Spring spacer
     
    U-bolts
     
    Anchor plate
     
    U-bolt nuts
     

  8.  
  9. Tighten in a crisscross pattern to:
    1. Express/Savana and 2005-06 Avalanche

      1500 series: 53 ft. lbs. (72 Nm)
       
      2500 series: 110 ft. lbs. (150 Nm)
       

    2.  
    3. 2007 Avalanche

      1500 series: 74 ft. lbs. (100 Nm)
       
      2500 series: 118 ft. lbs. (160 Nm)
       

    4.  

  10.  
  11. Tighten the front hanger bracket nut to 110 ft. lbs. (150 Nm) on Express/Savana and 2005-06 Avalanche or 70 ft. lbs. (95 Nm) on 2007 Avalanche.
  12.  
  13. Tighten the rear hanger bracket nut to 70 ft. lbs. (95 Nm).
  14.  
  15. Install the fuel tank for left side applications.
  16.  
  17. Install the trailer hitch if equipped.
  18.  
  19. Connect the RTD sensors, if equipped
  20.  
  21. Remove the rear axle support.
  22.  
  23. Remove the safety stands. Lower the vehicle.
  24.  

 
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