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Chevy Astro, GMC Safari Repair Manual 1985-2005Click To Enlarge Product Image

Chevy Astro, GMC Safari Minivan Repair Manual 1985-2005

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This Haynes DIY repair and service manual, covers 1985-2005 Chevrolet Astro and GMC Safari minivans.

Note: this manual DOES NOT include All-Wheel Drive info.


Book Excerpt: 1985-2005 Chevy Astro, GMC Safari Minivan Repair Manual

CLUTCH AND DRIVETRAIN

DRIVESHAFT | REMOVAL AND INSTALLATION
(Refer to illustration 12.3)

REMOVAL

  1. Disconnect the negative cable from the battery. Place the cable out of the way so that it cannot accidentally come into contact with the negative terminal of the battery, as this would once again allow power into the electrical system of the vehicle.

    CAUTION: On models equipped with an anti-theft audio system, disable the anti-theft feature before performing any operation that requires disconnecting the battery or disrupting power to the stereo ( see the anti-theft audio system procedures at the front of this manual).

  2. Raise the vehicle on a hoist and support it securely on jack stands. Place the transmission in Neutral with the parking brake off.
  3. Place paint marks on the driveshaft and the differential flange in line with each other (see illustration). This is to make sure the driveshaft is reinstalled in the same position to preserve the balance.
  4. Remove the rear universal joint strap bolts and the straps. Turn the driveshaft (or tires) as necessary to bring the bolts into the most accessible position.
  5. Tape the bearing caps to the spider to prevent the caps from coming off during removal.
  6. Lower the rear of the driveshaft and then slide the front out of the transmission. Do not pry on the universal joint or yoke. Avoid making a sharp angle between the joint and yoke, which would break the joint.

    Inspect the joint for burrs, which can damage the transmission seal, and the yoke splines for signs of wear. If servicing the driveshaft, don't clamp the tube in a vise, because this could deform it and affect its balance.

  7. To prevent loss of fluid and protect against contamination while the driveshaft is out, wrap a plastic bag over the transmission housing and hold it in place with a rubber band.
  8. INSTALLATION

  9. Remove the plastic bag on the transmission and wipe the area clean. Inspect the oil seal carefully. Procedures for replacement of this seal can be found in Chapter 7.
  10. Slide the front of the driveshaft into the transmission.
  11. Raise the rear of the driveshaft into position, checking to be sure that the marks are in perfect alignment. If not, turn the rear wheels to match the pinion flange and the driveshaft.
  12. Remove the tape securing the bearing caps and install the straps and bolts. Tighten the bolts to the specified torque.

STEERING AND SUSPENSION SYSTEMS
COIL SPRING | REMOVAL AND INSTALLATION

REMOVAL
(Refer to illustrations 8.5 and 8.7)

  1. Loosen the front wheel lug nuts, raise the vehicle and place it securely on jack stands.Remove the wheel.
  2. Remove the shock absorber (see Section 3).
  3. Remove the stabilizer bar link bolt (see Section 2).
  4. Disconnect the outer tie-rod end from the steering knuckle (see Section 17).
  5. Install a suitable internal type spring compressor in accordance with the tool manufacturer's instructions (see illustration).

    Compress the spring enough to relieve all pressure from the spring seats ( but don't compress it anymore than necessary, or it could be ruined). When you can wiggle the spring, its compressed enough. ( You can buy a suitable spring compressor at most auto part stores or rent one from a tool rental yard).

  6. Support the lower control arm with a floor jack.

  7. Remove the control arm pivot bolts and nuts (see illustration).
  8. Pull the lower control arm down and to the rear, then guide the compressed coil spring out. Do not use force.
  9. If the coil spring is being replaced, carefully unscrew the spring compressor.
  10. INSTALLATION

  11. Inspect the upper and lower spring insulators. If either insulator is cracked or excessively worn, replace it. Inspect the coil spring for chips in the corrosion protection coating. If the coating has been chipped or damaged, replace the spring.
  12. If the coil spring is being replaced, install the spring compressor and compress the spring.
  13. With the lower spring insulator in place, position the spring on the lower control arm with the flat end of the spring facing down. The identification tape should be toward the lower control arm.

    Make sure the tapered end seats on the lower control arm with the lower end of the spring seated in the lowest part of the spring seat.

    The end of the spring must cover all or part of one of the drain holes in the lower control arm, but the other hole must not be covered. The top spring insulator should also be in place.


TABLE of CONTENTS:
  • Introduction: Vehicle identification numbers; Buying parts; Maintenance techniques, and more.
  • Tune-up and routine maintenance
  • Four-cylinder engine
  • V6 engine
  • General engine overhaul procedures
  • Cooling, heating and air conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions and engine control systems
  • Manual transmission
  • Automatic transmission
  • Clutch and drivetrain
  • Brakes
  • Steering and suspension systems
  • Body
  • Chassis electrical systems
  • Wiring diagrams
Subject: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Chevrolet Astro, GMC Safari service, maintenance, repair. ISBN-10: 1563926962 | ISBN-13: 9781563926969 | Haynes 24010

  • Publisher: Haynes Manuals
  • Pages: 320 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-1-56392-696-9
  • Years: 1985 - 2005