GM fullsize AWD Van Info thread

[86cj]

Factory GM AWD availability:

GM offered fullsize AWD van's as either a Chevrolet Express or GMC Savana from 2003-2014 model years.

All GM AWD vans came equipt with the 5.3L engine and 4L60E transmission.

A 2500 version was offered in the 2003 model year only. All other fullsize AWD vans were 1500.



There was never a factory 3500 AWD offering from GM.
However Quigly has offered 2500 and 3500 4X4 converted vans which have been sold at GM dealerships.

AWD was available in either cargo or passenger versions. I have never found a cab/chassis van with AWD, I don't believe they were ever available from the factory. If someone can prove me wrong please do.

I have read (without any real verification) that the AWD van's share a chassis with the AWD Avalanche/Tahoe and that they are a completely different chassis then the 1500/2500/3500 RWD van's. Again if someone has credible information to the contrary please let me know so I can correct this.

Can you show us a picture of the Dana 60 axle under the van? This thread is the only good info you can find on these AWD Vans so we have to sweat the details, I wish I had it when I got the Van bug........

The 2500 AWD GVW rating is the same as the newer 1500's that use the 8.6" 10 bolt, no need for a special axle. The GM 2WD 8 lug 3/4 or 1 ton van did use a Dana 60 but mostly a GM corporate 9.5 or 10.5 and rarely a full float after 2003 unless it was a diesel. Dana has made a 60 series semi-float "non 8 lug" before, I think it was an old F-150 and an old Jeep J-20 not sure...................

The 7300lb GVW 2500 AWD is just an early 7300lb GVW 1500 AWD, 1500's had a 7200lb GVW. It's not a Unicorn with a Legendary 6 lug Dana 60........Anybody with a 2500 AWD have pictures of the rear axle?

 

[dleeallen]

Any experience here with spark plugs on these vans? I need to replace mine and wonder if there is any experience with value in getting upgrade plugs or if I should just go with regular replacements. Same on the plug wires. I assume there wouldn't be much to gain, but figured I would ask just to be sure!

 

[Choff]

I had my mechanic put stock GM Plugs and wires. Now just hit 190,000 miles on 2005 GMC AWD Savana Van with 5.3, runs great !!
Stick with GM Proven on plugs, mine GM Stock set was in van since new , that is 13 years

 

[christ0pher_m]

The 7300lb GVW 2500 AWD is just an early 7300lb GVW 1500 AWD, 1500's had a 7200lb GVW. It's not a Unicorn with a Legendary 6 lug Dana 60........Anybody with a 2500 AWD have pictures of the rear axle?

Here is my 2500 AWD rear axle, rust and all

 

[blazen71]

I'll get some pics up this week. Honestly the axle is the same as any other Semi-floating Dana 60 van axle. I pulled a G80 Gov-Loc out of a semi floating 8-lug Dana 60 van axle and it swapped right into mine.

 

[DRLexpress]

Not to highjack thread but since we a talking about axles. I would like to put a 14 bolt under the rear of my 2004 2 wheel drive 2500. I can find 14 bolts for pre 2003 but hard to find for 2003 on, diesel only I think. What is the difference in year models. I am pretty sure the width and the spring spacing is the same.

Doug

 

[blazen71]

Van axles are usually wider. And at some point they went from drum brakes to disc.

 

[DRLexpress]

Sorry, I was talking about van axles. Pre 2003 Express 2500 and 2003 and on Express 2500. They seem to have quit using the 14 bolts in 2002 on anything except the diesels.
I would gladly do a disc brake conversion in order to get an full float axle.

Doug

 

[blazen71]

http://www.billavista.com/tech/Articles/14-Bolt_Bible/index.html

 

[On Belay]

Any experience here with spark plugs on these vans? I need to replace mine and wonder if there is any experience with value in getting upgrade plugs or if I should just go with regular replacements. Same on the plug wires. I assume there wouldn't be much to gain, but figured I would ask just to be sure!

https://www.amazon.com/gp/product/B01F0OSFHK/ref=oh_aui_search_detailpage?ie=UTF8&psc=1

Trust me. Getting to the front plugs without them is next to impossible.

 

[Scotty D]

Do I need a transponder key for my 2009 express cargo AWD?
Lost my hide a key down in Baja

 

[blazen71]

Do I need a transponder key for my 2009 express cargo AWD?
Lost my hide a key down in Baja

http://www.programautokeys.com/mobile/classified/-chevrolet-express-van-listing-8806.aspx

 

[86cj]

DANA 60

Here is my 2500 AWD rear axle, rust and all


View attachment 435663

That clearly is a Dana 60, so now we all know that really is the only difference other than a fourth leaf spring reported by some. GM has a habit of building the same configuration without changes to a fault, with the GVW being almost the same I was skeptical, thanks for clearing things up.........

 

[blazen71]

Sorry, I was talking about van axles. Pre 2003 Express 2500 and 2003 and on Express 2500. They seem to have quit using the 14 bolts in 2002 on anything except the diesels.
I would gladly do a disc brake conversion in order to get an full float axle.

Doug

Swap in a full float dana 60 from a 3500 van.

 

[temporarydweller]

Do I need a transponder key for my 2009 express cargo AWD?
Lost my hide a key down in Baja

According to the parts catalog it may or may not have a transponder in that year. If you look at the base of your key where the metal goes into a the plastic, look for a small circle with a plus in it. If it does have it, that means its a transponder key.