The Chevy Express 2500 van is a 3/4-ton commercial vehicle. Chevrolet has manufactured these vans since 1996. When you turn the key to the start position, it sends an electrical impulse to the solenoid, which in turn activates the starter. The starter gear engages the flywheel and starts your van. When this gear fails to properly engage with the flywheel, the van is unable to start and you will need to replace the starter. Someone with no experience should be able to complete this project in an hour or less, so save your money and make the repair yourself.
- Skill level:
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Things you need
- Automobile jack
- Jack stand
- Wheel chocks
- Masking tape
- Metric socket set
- Metric wrench set
Lift the bonnet and prop it open. Disconnect the negative battery terminal using a wrench to loosen the nut. Place wheel chocks behind the rear wheels of the van.
Raise the Express van on the driver's side, using the jack. Place a jack stand under the frame near the jacking point. Raise the jack stand up to the frame.
Remove the bracket and heat shield from the starter, using a wrench to detach the retaining bolts. Mark the electrical wires on the starter using the masking tape and a market to note their proper locations. Disconnect the wires using a wrench to detach the nuts.
Remove the starter mounting bolts using a socket and ratchet. Pull the starter away from the engine. Some Chevy starters have shims in place to fit the starter properly. If your van has these shims, be sure to note their proper location for replacement when you put the new starter on.
Position the new starter and any shims. Tighten the bolts using the socket and ratchet. Connect the wires and tighten the nuts with a wrench. Replace the heat shield and bracket and tighten the retaining bolts with the wrench.
Remove the jack stand from under the van and lower the vehicle to the ground. Reconnect the battery terminal and tighten the nut with a wrench.
Tips and warnings
- Wearing safety glasses when working under the vehicle will prevent eye injuries caused by dirt and foreign objects.
- Be sure to disconnect the battery as instructed. Failure to do so is dangerous and could result in electrical shock.
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