At Removal & Installation

2002-03 AUTOMATIC TRANSMISSIONS

Removal & Installation - Avalanche, Escalade, Sierra, Silverado, Suburban, Tahoe & Yukon (4L60-E & 4L65-E)

APPLICATION

TRANSMISSION APPLICATION

REMOVAL & INSTALLATION

Application Transmission Model (RPO Code)Cadillac

Escalade5.3L 4L60-E (M30)6.0L 4L65-E (M32)

Escalade ESV 6.0L (2003) 4L65-E (M32)Escalade EXT 6.0L 4L65-E (M32)

ChevroletAvalanche 5.3L 4L60-E (M30)Silverado 1500

4.3L, 4.8L & 5.3L 4L60-E (M30)6.0L 4L65-E (M32)

Suburban 5.3L 4L60-E (M30)Tahoe 4.8L & 5.3L 4L60-E (M30)

GMCSierra 1500

4.3L, 4.8L & 5.3L 4L60-E (M30)6.0L 4L65-E (M32)

Yukon 4.8L & 5.3L 4L60-E (M30)Yukon XL 5.3L 4L60-E (M30)

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

CAUTION: When battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in

2003 Chevrolet Silverado 1500

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Avalanche, Escalade, Sierra, Silverado, Suburban, Tahoe & Yukon (4L60-E & 4L65-E)



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April-29-08 6:54:43 PM Page 1 © 2005 Mitchell Repair Information Company, LLC.

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TRANSMISSION

Removal

1. Record preset radio stations. Turn off lamps, accessories and ignition. Disconnect the negative battery cable.

2. Drain the transmission fluid. See DRAINING & REFILLING under LUBRICATION in SERVICING -AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.

3. Remove the rear driveshaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.

4. Support the transmission with a transmission jack. 5. Remove the transmission mount nuts. See Fig. 1 . 6. Remove the transmission support bolts and nuts. See Fig. 2 .

GENERAL INFORMATION before disconnecting battery.

CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.



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Fig. 1: Removing/Installing Transmission Mount Nuts Courtesy of GM



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Fig. 2: Removing/Installing Transmission Support Bolts & Nuts Courtesy of GM

7. Raise the transmission slightly and remove the transmission support from the vehicle. 8. Remove the exhaust pipe. 9. Remove the starter motor. See appropriate STARTERS article in ELECTRICAL.

10. If equipped, remove the transfer case. See appropriate REMOVAL & INSTALLATION article as follows:

For Escalade, Escalade EXT, Yukon Denali and Yukon XL, see TRANSFER CASE ASSEMBLY REPLACEMENT . See REMOVAL & INSTALLATION - SIERRA & SILVERADO article in TRANSFER CASES.



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For Avalanche, Tahoe, Yukon & Yukon XL, see TRANSFER CASE ASSEMBLY REPLACEMENT .

11. Remove the transmission mount bolts and mount. See Fig. 3 .

Fig. 3: Removing/Installing Transmission Bolts & Mount Courtesy of GM

12. Ensure the transmission manual shaft is positioned in mechanical park. 13. Remove the retainer that secures the cable to the bracket. See Fig. 4 . 14. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). See Fig.



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5 .

Fig. 4: Removing/Installing Cable-To-Bracket Retainer Courtesy of GM



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Fig. 5: Disconnecting Range Selector Cable Courtesy of GM

15. Depress the tangs and remove the cable from the bracket. 16. Remove the exhaust hanger bracket bolts and bracket. See Fig. 6 . 17. Remove the harness clip (1) from the fuel line bracket. See Fig. 7 .



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Fig. 6: Removing/Installing Exhaust Hanger Bracket Courtesy of GM



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Fig. 7: Identifying Harness Clip & PNP Switch Courtesy of GM

18. Disconnect the Park/Neutral Position (PNP) switch electrical connectors (2). See Fig. 7 . See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION in SERVICING - AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.

19. Disconnect the main electrical connector (1). See Fig. 8 . 20. Disconnect the Vehicle Speed Sensor (VSS) electrical connector (2). See Fig. 8 . 21. Remove the bolt that secures the fuel line bracket to the left side of the transmission. See Fig. 9 . 22. Remove the torque converter bolts. See Fig. 10 .



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Fig. 8: Identifying Main Electrical Connector & VSS Courtesy of GENERAL MOTORS CORP.



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Fig. 9: Removing/Installing Fuel Line Bracket-To-Left Side Transmission Bolt Courtesy of GM



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Fig. 10: Identifying Torque Converter Bolts Courtesy of GM

23. Disconnect the transmission oil cooler lines. See Fig. 11 . For additional information, see OIL COOLER



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LINE QUICK CONNECT FITTING under REMOVAL & INSTALLATION in SERVICING -AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.

24. Plug the transmission oil cooler line fittings. 25. Remove the fuel feed/return and Evaporative Emission (EVAP) return pipe bracket nut. See Fig. 12 . 26. Remove the lower right transmission bolt and stud. See Fig. 13 . 27. Remove the remaining transmission studs and bolt. See Fig. 14 .

Fig. 11: Disconnecting Transmission Oil Cooler Lines Courtesy of GM



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Fig. 12: Removing/Installing EVAP Return Pipe Bracket Nut Courtesy of GM



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Fig. 13: Removing Lower Right Transmission Bolt & Stud Courtesy of GM



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Fig. 14: Removing/Installing Remaining Transmission Studs & Bolts Courtesy of GM

28. Install the Converter Holding Strap (J-21366) onto the transmission in order to retain the torque converter.

29. Pull the transmission straight back. 30. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube. 31. Install the converter holding strap to the bellhousing in order to retain the torque converter. 32. Flush the transmission oil cooler and cooling lines if necessary. See OIL COOLER FLUSHING &

FLOW CHECK under LUBRICATION in SERVICING - AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.

Installation

1. Raise the transmission into place while simultaneously installing the fluid indicator tube. 2. Remove the converter holding strap.



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3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand.

4. Install transmission studs and bolt. See Fig. 14 . Tighten the bolt/studs to specification. See TORQUE SPECIFICATIONS .

5. Install the lower right transmission stud and bolt. See Fig. 13 . Tighten the bolt/stud to specification. See TORQUE SPECIFICATIONS .

6. Install the fuel feed/return and EVAP return pipe bracket nut. See Fig. 12 . Tighten the nut to specification. See TORQUE SPECIFICATIONS .

7. Remove the plugs from the transmission oil cooler line fittings. 8. Connect the transmission oil cooler lines. See Fig. 11 . For additional information, see OIL COOLER

LINE QUICK CONNECT FITTING under REMOVAL & INSTALLATION in SERVICING - AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.

9. Install the torque converter bolts. See Fig. 10 . Tighten the bolts to specification. See TORQUE SPECIFICATIONS .

10. Install the bolt that secures the fuel line bracket to the left side of the transmission. See Fig. 9 . Tighten the bolt to specification. See TORQUE SPECIFICATIONS .

11. Connect the VSS electrical connector (2). See Fig. 8 . 12. Connect the main electrical connector (1). See Fig. 8 . 13. Connect the PNP switch electrical connectors (2). See Fig. 7 . 14. Install the harness clip (1) to the fuel line bracket. See Fig. 7 . 15. Install the exhaust hanger bracket and bolts. See Fig. 6 . Tighten the bolts to specification. See TORQUE

SPECIFICATIONS . 16. Install the cable to the bracket. 17. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). See Fig. 5 . 18. Ensure the transmission manual shaft is positioned in mechanical park. 19. Install the retainer that secures the cable to the bracket. See Fig. 4 . 20. Install the transmission mount and bolts. See Fig. 3 . Tighten the bolts to specification. See TORQUE

SPECIFICATIONS . 21. If equipped, install the transfer case. See appropriate REMOVAL & INSTALLATION article as follows:

For Escalade, Escalade EXT, Yukon Denali and Yukon XL, see TRANSFER CASE ASSEMBLY REPLACEMENT . See REMOVAL & INSTALLATION - SIERRA & SILVERADO article in TRANSFER CASES. For Avalanche, Tahoe, Yukon & Yukon XL, see TRANSFER CASE ASSEMBLY REPLACEMENT .

22. Install the starter motor. See appropriate STARTERS article in ELECTRICAL. 23. Install the exhaust pipe. 24. Raise the transmission slightly and install the transmission support. See Fig. 2 . 25. Install the transmission support bolts and nuts. Tighten the bolts and nuts to specification. See TORQUE



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SPECIFICATIONS . 26. Install the transmission mount nuts. See Fig. 1 . Tighten the nuts to specification. See TORQUE

SPECIFICATIONS . 27. Remove the support from the transmission. 28. Install the rear driveshaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in

DRIVELINE/AXLES. 29. Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS . 30. Fill transmission with appropriate fluid to proper level. See LUBRICATION in SERVICING -

AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.

TRANSMISSION MOUNT

Removal

1. Raise and support the vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to the transmission support retaining nuts. See Fig. 1 . 4. Raise the transmission to take the weight off of the mount. 5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts. 6. Raise the transmission just enough to remove the transmission mount. 7. Remove the transmission mount from the vehicle.

Installation

1. Install the transmission mount to the vehicle. 2. Install the transmission mount to the transmission or transfer case adapter mounting bolts. Tighten the

bolts to specification. See TORQUE SPECIFICATIONS . 3. Lower the transmission. 4. Install the transmission mount to the transmission support retaining nut or nuts. See Fig. 1 . Tighten the

nut or nuts to specification. See TORQUE SPECIFICATIONS . 5. Remove the transmission jack. 6. Lower the vehicle.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)EVAP Return Pipe Bracket Nut 15 (20)Exhaust Hanger Bracket Bolts 13 (17)Lower Right Transmission Stud & Bolt 37 (50)Torque Converter Bolts 46 (63)



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Transmission Mount Bolts 18 (25)Transmission Mount Nuts 37 (50)Transmission Mount-To-Transmission Or Transfer Case Adapter Mounting Bolts 37 (50)Transmission Mount-To-Transmission Support Retaining Nuts 30 (40)Transmission Studs & Bolt 37 (50)Transmission Support Bolts & Nuts 70 (95)

INCH Lbs. (N.m)Battery Cable Bolt 133 (15)Fuel Line Bracket-To-Left Side Transmission Bolt 89 (10)



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Removal & Installation - Avalanche, Sierra, Silverado, Suburban & Yukon (4L80-E & 4L85-E)

APPLICATION



TRANSMISSION

Application Transmission Model (RPO Code)Chevrolet

Avalanche 4L80-E (MT1) & 4L85-E (MN8)Cab & Chassis, & Silverado 4L80-E (MT1)Silverado 4L80-E (MT1)Suburban 4L80-E (MT1) & 4L85-E (MN8)

GMCCab & Chassis, & Sierra 4L80-E (MT1)Sierra 4L80-E (MT1)Yukon & Yukon XL 4L80-E (MT1) & 4L85-E (MN8)


CAUTION: When battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.


2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Avalanche, Sierra, Silverado, Suburban & Yukon (4L80-E & 4L85-E)



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Removal

1. Disconnect the negative (-) battery cable. 2. Drain the transmission fluid. See LUBRICATION in appropriate SERVICING article. 3. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in

DRIVELINE/AXLES. 4. Support the transmission with a suitable jack. 5. Remove the transmission mount nuts. See Fig. 1 .

Fig. 1: Removing/Installing Transmission Support Bolts & Nuts Courtesy of GENERAL MOTORS CORP.

6. Remove the transmission support bolts and nuts. See Fig. 1 . 7. Raise the transmission slightly and remove the transmission support from the vehicle. 8. Remove the exhaust manifold pipe. 9. Remove the transfer case, if equipped. See appropriate REMOVAL & INSTALLATION article in

TRANSFER CASES. 10. Remove the transmission mount bolts and mount. See Fig. 2 .



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Fig. 2: Removing/Installing Transmission Mount Bolts & Nuts Courtesy of GENERAL MOTORS CORP.

11. Ensure the transmission manual shaft is positioned in mechanical park. 12. Remove the retainer that secures the cable to the bracket. See Fig. 3 . 13. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). See Fig.

4 .



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Fig. 3: Removing/Installing Range Selector Cable From Bracket Courtesy of GM



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Fig. 4: Identifying Range Selector Lever Ball Stud Courtesy of GM

14. Depress the tangs and remove the cable from the bracket. 15. Disconnect the following electrical connectors:

Input speed sensor (1). See Fig. 5 . Output speed sensor (3). Park/neutral position (PNP) switch (5). Transmission (4).



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Fig. 5: Identifying Electrical Connectors Courtesy of GENERAL MOTORS CORP.

16. Disconnect the oxygen sensor (HO2S) electrical connector. 17. Disconnect the wire harness clip (2) from the bracket on the left side of the transmission. 18. Cut the tie strap to separate the vent hose from the wiring harness. 19. Remove the flywheel inspection cover. See Fig. 6 .



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Fig. 6: Removing/Installing Flywheel Inspection Cover Courtesy of GENERAL MOTORS CORP.

20. Mark the torque converter to flywheel orientation. 21. Remove the torque converter bolts. 22. Remove the exhaust hanger mounting bracket bolts and brackets, if equipped. See Fig. 7 and Fig. 8 .



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Fig. 7: Removing/Installing Exhaust Hanger Mounting Bracket (6.0L) Courtesy of GENERAL MOTORS CORP.



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Fig. 8: Removing/Installing Exhaust Hanger Mounting Bracket (8.1L) Courtesy of GENERAL MOTORS CORP.

23. Disconnect the transmission oil cooler lines. See Fig. 9 . 24. Plug the transmission oil cooler line fittings. 25. Remove the stud on the left side of the transmission. See Fig. 10 . 26. Remove the remaining transmission studs. See Fig. 11 .



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Fig. 9: Disconnecting Transmission Oil Cooler Lines Courtesy of GM



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Fig. 10: Removing/Installing Left Side Transmission Stud Courtesy of GENERAL MOTORS CORP.



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Fig. 11: Removing/Installing Transmission Studs Courtesy of GM

27. Install the Converter Holding Strap (J-21366) onto the transmission bell housing to retain the torque converter.

28. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube. Pull the transmission straight back.

29. Remove the transmission from the vehicle.

Installation

1. Install the transmission to the vehicle. 2. Raise the transmission into place and remove the converter holding strap from the transmission. 3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the

torque converter. The torque converter must rotate freely by hand. 4. Install transmission studs and bolt. See Fig. 11 . Tighten the studs to specification. See TORQUE



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SPECIFICATIONS . 5. Install the stud on the left side of the transmission. See Fig. 10 . Tighten the stud to specification. See

TORQUE SPECIFICATIONS . 6. Remove the plugs from the transmission oil cooler line fittings. See Fig. 9 . Tighten the nut to

specification. See TORQUE SPECIFICATIONS . 7. Connect the transmission oil cooler lines. Tighten to specification. See TORQUE SPECIFICATIONS . 8. If equipped, install the exhaust hanger mounting brackets and bolts. See Fig. 7 and Fig. 8 . Tighten the

bolts to specification. See TORQUE SPECIFICATIONS . 9. Align the torque converter to the flywheel.


11. Install the flywheel inspection cover. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .

12. Connect the following electrical connectors: Input speed sensor (1). See Fig. 5 . Output speed sensor (3). PNP switch (5). Transmission (4).

13. Connect the HO2S electrical connector. 14. Connect the wire harness clip (2) to the bracket on the left side of the transmission. 15. Depress the tangs and install the cable to the bracket. 16. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). See Fig. 4 . 17. Ensure the transmission manual shaft is positioned in mechanical park. 18. Install the retainer that secures the cable to the bracket. See Fig. 3 . 19. Install the transmission mount and bolts. See Fig. 2 . Tighten bolts to specification. See TORQUE

SPECIFICATIONS . 20. Install the transfer case, if equipped. See appropriate REMOVAL & INSTALLATION article in

TRANSFER CASES. 21. Install the exhaust manifold pipe. Tighten bolts to specification. See TORQUE SPECIFICATIONS . 22. Install the transmission support. See Fig. 1 . 23. Install the transmission support bolts and nuts. Tighten the bolts and nuts to specification. See TORQUE

SPECIFICATIONS . 24. Install the transmission mount nuts. See Fig. 1 . Tighten the nuts to specification. See TORQUE

SPECIFICATIONS . 25. Remove the support from the transmission. 26. Install the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in

DRIVELINE/AXLES. 27. Connect the negative (-) battery cable. 28. Fill transmission with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING

article.



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TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)Exhaust Manifold Pipe Nuts 39 (50)Flywheel Inspection Cover 24 (33)Heat Shield-To-Transmission Bolts 13 (17)Oil Pan Drain Plug 13 (18)Oxygen Sensor 31 (42)PNP Switch Bolts 18 (25)Range Selector Bracket Bolts 18 (25)Torque Converter Bolts 44 (60)Transfer Case Adapter Nut 37 (50)Transmission Mount Bolts 18 (25)Transmission Mount Nuts 37 (50)Transmission Studs 37 (50)Transmission Support Bolts & Nuts 75 (95)

INCH Lbs. (N.m)Battery Cable Bolt 133 (15)Exhaust Hanger Mounting Bracket Bolts 106 (12)



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A/T Removal & Installation - Sierra & Silverado (Allison LCT 1000)

APPLICATION



Application Engine Size Transmission Model (RPO Code)

ChevroletCab & Chassis Silverado 3500, Silverado 2500 HD & Silverado 3500

6.6L Or 8.1L

LCT 1000 (M74)

GMCCab & Chassis Sierra 3500, Sierra 2500 HD & Sierra 3500

6.6L Or 8.1L

LCT 1000 (M74)


CAUTION: When battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

CAUTION: If replacing a failed transmission, the "FastLearn" (adapt) procedure must be performed. This can be done in one step using a scan tool. If this procedure is not done, the Transmission Control Module's (TCM) adaptive values will still be at the settings that it learned for the old transmission, and will be in slow adaptive mode. Under these conditions, it would take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission.

NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect


2002-03 AUTOMATIC TRANSMISSIONS A/T Removal & Installation - Sierra & Silverado (Allison LCT 1000)



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TRANSMISSION

Removal (6.6L)

1. Disconnect both of the negative (-) battery cables. 2. Remove the transmission fluid level indicator. 3. Raise the vehicle until the right front wheel and tire can be removed. 4. Remove the right front wheel and tire. 5. Remove the right front wheel house inner panel retainers (2). See Fig. 1 .

fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.



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Fig. 1: Locating Right Front Wheel House Inner Panel Retainers Courtesy of GENERAL MOTORS CORP.

6. Disconnect any harness retainers attached to the inner panel. 7. Remove the inner panel (2). 8. Remove the positive (+) battery cable nut and cable from the starter. 9. Remove the solenoid nut and wire from the starter. See Fig. 2 .

10. Remove the starter motor bolts and reposition the starter. See Fig. 3 . 11. Remove the engine protection shield bolts and shield. See Fig. 4 .



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Fig. 2: Removing/Installing Solenoid Nut & Wire From Starter Courtesy of GENERAL MOTORS CORP.



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Fig. 3: Removing/Installing Starter Motor Bolts Courtesy of GENERAL MOTORS CORP.



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Fig. 4: Removing/Installing Engine Protection Shield Courtesy of GENERAL MOTORS CORP.

12. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts through the starter opening. Have an assistant rotate the engine while aligning the bolts.

13. Remove the torque converter bolts. See Fig. 5 .

CAUTION: Rotate the engine clockwise ONLY, rotating the engine counterclockwise may loosen the crankshaft balancer bolt.



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Fig. 5: Identifying Torque Converter Bolts Courtesy of GENERAL MOTORS CORP.

14. Completely raise the vehicle. 15. Drain the transmission fluid. See LUBRICATION in appropriate SERVICING article. 16. Disconnect the shift cable from the selector lever ball stud (5) and remove the cable from the bracket (3).

See Fig. 6 . 17. Remove the shift cable bracket bolts and bracket (2) from the transmission. See Fig. 7 .



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Fig. 6: Disconnecting/Connecting Shift Cable From Selector Lever Ball Stud Courtesy of GENERAL MOTORS CORP.



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Fig. 7: Identifying Bracket Bolts & Bracket From Transmission Courtesy of GENERAL MOTORS CORP.

18. Reposition the bracket with the cable attached off to the side. 19. Remove the fuel line retainer (1) bolts on the left side of the transmission. See Fig. 8 . 20. Remove the fuel line bracket nut from the converter housing stud. See Fig. 9 . 21. Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. See Fig. 10 . 22. Disconnect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4 wheel drive

(4WD), the output speed sensor is located on the transfer case and will be disconnected later. See Fig. 10 .



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Fig. 8: Removing/Installing Fuel Line Retainer Bolts Courtesy of GENERAL MOTORS CORP.



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Fig. 9: Removing/Installing Fuel Line Bracket Nut From Converter Housing Stud Courtesy of GENERAL MOTORS CORP.



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Fig. 10: Identifying Speed Sensors & Electrical Connectors Courtesy of GENERAL MOTORS CORP.

23. Disconnect the transmission main electrical connector. The Connector Removal Tool (J-44257) may be used, but is not required. See Fig. 11 .

24. Disconnect the Park/Neutral Position (PNP) switch electrical connector. 25. Remove the exhaust hanger bolts and reposition the hanger. See Fig. 12 .



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Fig. 11: Disconnecting/Connecting Transmission Main Electrical Connector Courtesy of GENERAL MOTORS CORP.



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Fig. 12: Removing/Installing Exhaust Hanger Bolts Courtesy of GENERAL MOTORS CORP.

26. If the vehicle is a 2 wheel drive (2WD), remove the drive shaft. See appropriate DRIVE SHAFT & UNIVERSAL JOINTS article in DRIVELINE/AXLES.

27. Support the transmission with a transmission jack. 28. If the vehicle is a 2WD, remove the transmission mount nuts. See Fig. 13 . 29. If the vehicle is a 2WD, remove the transmission support bracket bolts. See Fig. 14 . 30. If the vehicle is a 2WD, remove the transmission support bolts and nuts. See Fig. 14 . 31. Remove the transmission mount bolts (1). See Fig. 15 .



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Fig. 13: Removing/Installing Transmission Mount Nuts (2WD) Courtesy of GENERAL MOTORS CORP.



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Fig. 14: Removing/Installing Transmission Support Bracket Nuts & Bolts (2WD) Courtesy of GENERAL MOTORS CORP.



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Fig. 15: Identifying Transmission Mount Bolts Courtesy of GENERAL MOTORS CORP.

32. Remove the transmission mount. 33. If the vehicle is equipped with 4WD, remove the transfer case. See appropriate REMOVAL &

INSTALLATION article in TRANSFER CASES. 34. Reposition any wiring harness branches out of the way. 35. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other

related components. See Fig. 16 . 36. Disconnect the transmission oil cooler lines (1 and 2) from the transmission. See Fig. 17 .



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Fig. 16: Securing Safety Chain Around Transmission Courtesy of GENERAL MOTORS CORP.



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Fig. 17: Identifying Transmission Oil Cooler Lines Courtesy of GENERAL MOTORS CORP.

37. Plug the transmission oil cooler line fittings in the transmission case, if necessary. 38. If the vehicle is equipped with a Power Take Off (PTO) unit, disconnect and/or remove any necessary

components to facilitate transmission removal. 39. Remove the transmission fill tube nuts from the converter housing studs. See Fig. 18 . 40. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the

bracket. See Fig. 19 .



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Fig. 18: Removing/Installing Transmission Fill Tube Nuts Courtesy of GENERAL MOTORS CORP.



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Fig. 19: Removing/Installing Wire Harness & Vent Tube Bracket Nut Courtesy of GENERAL MOTORS CORP.

41. Remove the remaining converter housing bolts and studs. See Fig. 20 . 42. Separate the transmission from the engine. 43. Install Converter Holding Strap (J-21366) to the converter housing in order to keep the torque converter

from sliding off of the turbine shaft. See Fig. 21 .



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Fig. 20: Removing/Installing Converter Housing Bolts & Studs Courtesy of GENERAL MOTORS CORP.



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Fig. 21: Installing Converter Holding Strap Courtesy of GENERAL MOTORS CORP.

44. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube. 45. Remove the converter holding strap.

Installation (6.6L)

1. Install converter holding strap to the converter housing in order to keep the torque converter from sliding off of the turbine shaft. See Fig. 21 .

2. Raise the transmission into place while simultaneously installing the transmission fill tube. 3. Remove the converter holding strap.

CAUTION: Do not install the transmission by drawing it to the engine using the studs and bolts.



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4. Align the transmission with the engine using the alignment dowels located at the rear of the engine. See Fig. 20 .

5. Install the converter housing bolts and studs. Tighten the bolts and studs to specification. See TORQUE SPECIFICATIONS .

6. Install the wire harness/vent tube bracket and nut to the converter housing stud. See Fig. 19 . Tighten the nut to specification. See TORQUE SPECIFICATIONS .

7. Install the transmission fill tube and nuts to the converter housing studs. See Fig. 18 . Tighten the nuts to specification. See TORQUE SPECIFICATIONS .

8. If the vehicle is equipped with a PTO unit, connect and/or install the components at this time. 9. Remove the safety chain from around the transmission. See Fig. 16 .

10. Install the transfer case, if the vehicle is equipped with 4WD. 11. If the vehicle is a 2WD, install the transmission mount. 12. If the vehicle is a 2WD, install the transmission mount bolts (1). See Fig. 15 . Tighten the bolts to

specification. See TORQUE SPECIFICATIONS . 13. Install the transmission support. 14. If the vehicle is a 2WD, install the transmission support bolts and nuts. 15. If the vehicle is a 2WD, install the transmission support bracket bolts. See Fig. 14 . Tighten the bolts/nuts

to specification. See TORQUE SPECIFICATIONS . 16. If the vehicle is a 2WD, install the transmission mount nuts. See Fig. 13 . Tighten the nuts specification.

See TORQUE SPECIFICATIONS . 17. If the vehicle is a 2WD, install the transmission mount nuts. Tighten the nuts to specification. See

TORQUE SPECIFICATIONS . 18. If the vehicle is a 2WD, install the drive shaft. 19. Position the exhaust hanger and install the bolts. See Fig. 12 . Tighten the bolts to specification. See

TORQUE SPECIFICATIONS . 20. Position the wiring harness branches. 21. Connect the PNP switch electrical connectors. 22. Connect the transmission main electrical connector (2). See Fig. 22 .

CAUTION: Ensure that the torque converter can be rotated before tightening the bolts and studs.



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Fig. 22: Connecting Transmission Main Electrical Connector Courtesy of GENERAL MOTORS CORP.

23. Connect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and has been connected during the transfer case installation. See Fig. 10 .

24. Connect the turbine speed sensor (1) and the input speed sensor (2) electrical connectors. 25. Install the fuel line bracket and nut to the transmission converter housing stud. See Fig. 9 . Tighten the

nut to specification. See TORQUE SPECIFICATIONS . 26. Install the fuel line retainer (1) and bolts to the left side of the transmission. See Fig. 8 . Tighten the bolts

to specification. See TORQUE SPECIFICATIONS . 27. Install the shift cable bracket (2) and bolts to the transmission. See Fig. 7 . Tighten the bolts to

specification. See TORQUE SPECIFICATIONS . 28. Install the shift cable to the bracket (3) and the selector lever ball stud (5). See Fig. 6 . 29. Remove the access hole cover (1) on the converter housing in order to rotate the converter and align the

first torque converter bolt. See Fig. 23 .



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Fig. 23: Removing Access Hole Cover Courtesy of GENERAL MOTORS CORP.


31. Install the converter housing access hole cover. 32. Install the engine protection shield and bolts. See Fig. 4 . Tighten the bolts to specification. See

TORQUE SPECIFICATIONS . 33. Position and install the starter motor bolts. See appropriate STARTERS article in ELECTRICAL. See

Fig. 3 . Tighten the bolts to specification. See TORQUE SPECIFICATIONS . 34. Install the solenoid wire and nut to the starter. See Fig. 2 . Tighten the nut to specification. See TORQUE

SPECIFICATIONS . 35. Install the positive battery cable and nut to the starter. Tighten the nut to specification. See TORQUE

SPECIFICATIONS .



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36. Install the inner panel (2). 37. Connect any harness retainers to the inner panel. 38. Install the right front wheel house inner panel retainers (2). See Fig. 1 . 39. Install the right front wheel and tire. 40. Remove the plugs from the transmission oil cooler line fittings in the transmission case, if necessary. 41. Flush the transmission oil cooler and lines, if necessary. 42. Connect the transmission oil cooler lines (1 and 2) to the transmission. See Fig. 17 . 43. Lower the vehicle. 44. Connect both negative (-) battery cables. 45. Fill the transmission with new transmission fluid. 46. Install the transmission fluid level indicator. 47. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. See

PROGRAMMING in appropriate DIAGNOSIS article.

Removal (8.1L)

1. Disconnect the negative (-) battery cable. 2. Remove the transmission fluid level indicator. 3. Raise and suitably support the vehicle. 4. Remove the engine protection shield bolts and shield. See Fig. 4 . 5. Remove the starter motor bolts and position the starter motor aside. See Fig. 24 .



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Fig. 24: Removing/Installing Starter Motor & Bolts Courtesy of GENERAL MOTORS CORP.

6. Drain the transmission fluid, if necessary.



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7. If the vehicle is a 2 wheel drive (2WD), remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINT article in DRIVELINE/AXLES.

8. Support the transmission with a transmission jack. 9. If the vehicle is a 2WD, remove the transmission mount nuts. See Fig. 13 .

10. If the vehicle is a 2WD, remove the transmission support bracket bolts. See Fig. 14 . 11. If the vehicle is a 2WD, remove the transmission support bolts and nuts. 12. If the vehicle is a 2WD, remove the transmission support. 13. If the vehicle is equipped with 4 wheel drive (4WD), remove the transfer case. 14. Remove the transmission mount bolts (1). See Fig. 15 . 15. Remove the transmission mount. 16. Disconnect the shift cable from the selector lever ball stud (5) and remove the cable from the bracket (3).

See Fig. 6 . 17. Remove the shift cable bracket bolts and bracket (2) from the transmission. See Fig. 7 . 18. Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. See Fig. 10 . 19. Disconnect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the

output speed sensor is located on the transfer case and will already be disconnected. 20. Disconnect the transmission main electrical connector. The connector removal tool may be used, but is

not required. See Fig. 11 . 21. Disconnect the park neutral position (PNP) switch electrical connector. 22. Remove the fuel line retainer (1) bolts on the left side of the transmission. See Fig. 8 . 23. Remove the transmission heat shield bolt and nut (4 and 5) and shield (3). See Fig. 25 .



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Fig. 25: Removing Transmission Heat Shield Bolt & Nut Courtesy of GENERAL MOTORS CORP.

24. Remove the exhaust pipe hanger bolts and reposition the hanger. See Fig. 12 . 25. Remove the transmission heat shield bolts (2) and shield (1). See Fig. 25 . 26. Remove the converter housing inspection cover bolts and cover. See Fig. 26 .



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Fig. 26: Removing Converter Housing Inspection Cover Bolts & Cover Courtesy of GENERAL MOTORS CORP.

27. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts through the starter opening. Have an assistant rotate the engine while aligning the bolts.

28. Remove the torque converter bolts (3). See Fig. 27 .



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Fig. 27: Identifying Torque Converter Bolts Courtesy of GENERAL MOTORS CORP.

29. Remove the transmission fill tube nuts from the converter housing studs. See Fig. 18 . 30. Remove the fuel line bracket nut from the converter housing stud. See Fig. 9 . 31. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the

bracket. See Fig. 19 . 32. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other

related components. See Fig. 16 . 33. Disconnect the transmission oil cooler lines (1 and 2) from the transmission. See Fig. 17 . 34. Plug the transmission oil cooler line fittings in the transmission case. 35. If the vehicle is equipped with a Power Take Off unit (PTO), disconnect and/or remove any necessary

components to facilitate transmission removal. 36. Remove the remaining converter housing bolts and studs. See Fig. 28 .



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Fig. 28: Identifying Converter Housing Bolts & Studs Courtesy of GENERAL MOTORS CORP.

37. Separate the transmission from the engine. 38. Install converter holding strap to the converter housing in order to keep the torque converter from sliding

off of the turbine shaft. See Fig. 21 . 39. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube. 40. Remove the converter holding strap.

Installation (8.1L)

1. Install converter holding strap to the converter housing in order to keep the torque converter from sliding off of the turbine shaft. See Fig. 21 .



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2. Raise the transmission into place while simultaneously installing the fill tube. 3. Remove the converter holding strap.

4. Align the transmission with the engine using the alignment dowels located at the rear of the engine. 5. Install the converter housing bolts and studs. See Fig. 28 . Tighten the bolts/studs to specification. See

TORQUE SPECIFICATIONS . 6. Position the wire harness/vent tube bracket and install the wire harness/vent tube bracket nut to the

converter housing stud. See Fig. 19 . Tighten the nut to specification. See TORQUE SPECIFICATIONS .

7. Install the fuel line bracket nut to the converter housing stud. See Fig. 9 . Tighten the nut to specification. See TORQUE SPECIFICATIONS .

8. Install the transmission fill tube nuts to the converter housing studs. See Fig. 18 . Tighten the nuts to specification. See TORQUE SPECIFICATIONS .

9. Remove the safety chain from around the transmission. See Fig. 16 . 10. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts

through the starter opening. Have an assistant rotate the engine while aligning the bolts. See Fig. 27 . 11. Install the torque converter bolts (3). Tighten the bolts to specification. See TORQUE

SPECIFICATIONS . 12. Install the converter housing inspection cover and bolts. See Fig. 26 . Tighten the bolts to specification.

See TORQUE SPECIFICATIONS . 13. Install the transmission heat shield (1) and bolts (2). See Fig. 25 . Tighten the bolts to specification. See

TORQUE SPECIFICATIONS . 14. Position the hanger and install the exhaust pipe hanger bolts. See Fig. 14 . Tighten the bolts to

specification. See TORQUE SPECIFICATIONS . 15. Install the transmission heat shield (3) and bolt/nut (4 and 5). See Fig. 25 . Tighten the bolt/nut to

specification. See TORQUE SPECIFICATIONS . 16. Install the fuel line retainer (1) bolts to the left side of the transmission. See Fig. 8 . Tighten the bolts to

specification. See TORQUE SPECIFICATIONS . 17. Connect the PNP switch electrical connector. 18. Disconnect the transmission main electrical connector (2). See Fig. 22 . 19. Connect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the output

speed sensor is located on the transfer case and will be disconnected later. See Fig. 10 . 20. Connect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. 21. Install the shift cable bracket (2) and bolts to the transmission. See Fig. 7 . Tighten the bolts to

specification. See TORQUE SPECIFICATIONS . 22. Connect the shift cable to the selector lever ball stud (5) and install the cable to the bracket (3). Connect

the shift cable to the selector lever ball stud (5) and install the cable to the bracket (3). See Fig. 6 . 23. Install the transmission mount.

CAUTION: Do not install the transmission by drawing it to the engine using the studs and bolts.



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24. Install the transmission mount bolts (1). See Fig. 17 . Tighten the bolts to specification. See TORQUE SPECIFICATIONS .

25. If the vehicle is equipped with 4WD, install the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.

26. If the vehicle is a 2WD, install the transmission support. See Fig. 14 . 27. If the vehicle is a 2WD, install the transmission support bolts and nuts. 28. If the vehicle is a 2WD, install the transmission support bracket bolts. Tighten the bolts/nuts to

specification. See TORQUE SPECIFICATIONS . 29. If the vehicle is a 2WD, install the transmission mount nuts. See Fig. 13 . Tighten the nuts to

specification. See TORQUE SPECIFICATIONS . 30. Remove the transmission jack from the transmission. 31. If the vehicle is a 2WD, install the drive shaft. 32. Position the starter motor and install the starter motor bolts. See Fig. 24 . Tighten the bolts to

specification. See TORQUE SPECIFICATIONS . 33. Install the engine protection shield and bolts. See Fig. 4 . Tighten the bolts to specification. See

TORQUE SPECIFICATIONS . 34. If the vehicle is equipped with a PTO unit, connect and/or install any necessary components. 35. Remove the plugs from the transmission oil cooler line fittings in the transmission case. 36. Flush the transmission oil cooler and lines, if necessary. See OIL COOLER FLUSHING under

LUBRICATION in appropriate SERVICING article. 37. Connect the transmission oil cooler lines (1 and 2) to the transmission. See Fig. 17 . 38. Lower the vehicle. 39. Connect the negative (-) battery cable. Tighten bolt to specification. See TORQUE

SPECIFICATIONS . 40. Fill transmission with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING

article. 41. Install the transmission fluid level indicator. 42. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. See

PROGRAMMING in appropriate DIAGNOSIS article.


TORQUE SPECIFICATIONS Application Ft. Lbs. (N.m)Battery Cable (Negative) 13 (17)Converter Housing Bolts & Stud 37 (50)Engine Protection Shield & Bolt 15 (20)Fuel Line Bracket Nut 13 (18)Fill Tube Nut-To-Converter Housing Stud 13 (18)Shift Cable Bracket Bolts 18 (25)



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Starter Motor Bolts6.6L 58 (78)8.1L 37 (50)

Torque Converter Bolts 44 (60)Transmission Heat Shield Bolts 13 (17)Transmission Mount Bolts 37 (50)Transmission Mount Nuts 30 (40)Transmission Support Bracket Bolts 70 (95)Wire Harness/Vent Tube Bracket 13 (18)

INCH Lbs. (N.m)Battery Positive Cable-To-Starter 80 (9)Converter Housing Inspection Cover Bolt 89 (10)Exhaust Hanger Pipe 106 (12)Fuel Line Retainer Bolts 22 (2.5)Wire-To-Starter Solenoid Nut 30 (3.4)



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At Removal & Installation

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