🔧 Express 3500 - Shock/“Strut” Replacement

Your Express 3500 does not use front MacPherson “struts” like many cars. It uses shock absorbers (front and rear). Replacing worn shocks restores ride control, braking stability, and reduces bouncing.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

Assumption: Stock suspension; instructions cover both front and rear shocks.

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⚠️ Safety & Precautions

• 🛑 Support the van with jack stands under the frame—never rely on a floor jack.
• 🛑 Chock the wheels and keep the transmission in PARK.
• 🛑 Let suspension hang slowly; keep hands clear of pinch points.
• 🛑 Use eye protection—rust and debris fall straight down.
• 🛑 No battery disconnect is required for shock replacement.

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🔧 Required Tools

You'll need the following tools for this repair:

• Wheel chocks
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• 22mm socket
• 1/2" drive ratchet
• 1/2" drive breaker bar
• Torque wrench (20-200 ft-lbs range)
• 15mm socket
• 18mm socket
• 21mm socket
• Combination wrench set (15mm-21mm)
• Penetrating oil
• Pry bar
• Hammer
• Wire brush
• Safety glasses
• Mechanic gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front shock absorbers (replace in pairs) - Qty: 2
• Rear shock absorbers (replace in pairs) - Qty: 2
• Front upper shock bushing/nut kit (if not included with shocks) - Qty: 1
• Rear shock mounting hardware kit (recommended in rust-belt) - Qty: 1

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📋 Before You Begin

• Park on level ground, set the parking brake, and place wheel chocks at the wheels staying on the ground.
• Spray all shock fasteners with penetrating oil (a thin oil that helps loosen rusted bolts) and wait 10-15 minutes.
• Crack the lug nuts loose with a 22mm socket and breaker bar (a long handle for extra leverage) before lifting.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and support the van

• Use a floor jack (rated 3-ton minimum) to lift the front (or rear) at the proper jacking point.
• Place jack stands (rated 3-ton minimum) under the frame rails and lower the van onto them.
• Remove the wheels using a 22mm socket and 1/2" drive ratchet.

Step 2: Replace the FRONT shocks (do one side at a time)

• Locate the front shock: it runs between the lower control arm area and the upper shock mount.
• Clean exposed threads with a wire brush, then respray with penetrating oil.
• Remove the lower shock bolt/nut using an 18mm socket and combination wrench set (15mm-21mm).
• Remove the upper stem nut from the shock using a 15mm socket (hold the stem as needed with a combination wrench).
• Pull the shock out. If it’s stuck, use a pry bar and light taps with a hammer.
• Install the new shock with the bushings/washer stack in the same order as removed.
• Snug the upper nut, then install the lower bolt.
• Final tighten:
  • Front lower shock bolt: Torque to 70 Nm (52 ft-lbs)
  • Front upper shock stem nut: Torque to 30 Nm (22 ft-lbs)
• Tip: Tighten the upper nut until bushings just swell.

Step 3: Replace the REAR shocks (do one side at a time)

• Support the rear axle lightly with the floor jack (rated 3-ton minimum) so it doesn’t drop when the shock is removed.
• Remove the lower rear shock bolt/nut using a 21mm socket and breaker bar.
• Remove the upper rear shock bolt/nut using a 21mm socket and combination wrench set (15mm-21mm).
• Remove the shock. If it’s stuck in the mount, use a pry bar and light taps with a hammer.
• Install the new rear shock in the same orientation as the old one.
• Hand-start both upper and lower bolts to prevent cross-threading.
• Final tighten:
  • Rear upper shock bolt: Torque to 100 Nm (74 ft-lbs)
  • Rear lower shock bolt: Torque to 100 Nm (74 ft-lbs)

Step 4: Reinstall wheels and lower the van

• Reinstall wheels using a 22mm socket and 1/2" drive ratchet.
• Lower the van off the jack stands using the floor jack.
• Tighten lug nuts in a star pattern using a torque wrench: Torque to 190 Nm (140 ft-lbs).

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✅ After Repair

• Bounce-test each corner by pushing down firmly; it should settle quickly without continued bouncing.
• Test drive at low speed first. Listen for clunks over bumps (often a loose lower bolt).
• Recheck lug nut torque with a torque wrench after 25-50 miles: Torque to 190 Nm (140 ft-lbs).
• No alignment is typically required for shock-only replacement on your Express 3500, but get it checked if tire wear or pulling was present.

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💰 DIY vs Shop Cost

Shop Cost: $650-$1,200 (parts + labor)

DIY Cost: $200-$500 (parts only)

You Save: $450-$700 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-4 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.