Removal Procedure
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
- Disconnect the negative battery cable. Battery Negative Cable Disconnection and Connection
Oil Level Indicator (1) - Remove
- Electrical Connector (1) @ Oil Level Indicator (3) - Unclip
- Oil Level Indicator Tube Bracket Bolt (2) - Remove
Oil Level Indicator Tube (1) - Remove
- Oil Level Indicator Tube Seal (2) - Remove and DISCARD
- Drain the cooling system. Cooling System Draining and Filling (LSY GE 47716) , or Cooling System Draining and Filling (LSY Static Fill) , or Cooling System Draining and Filling (LSY with V03 Static Fill) , or Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716) , or Cooling System Draining and Filling (LSY with V03 GE 47716) , or Cooling System Draining and Filling (LF4 Static Fill) , or Cooling System Draining and Filling (LF4 GE 47716)
- Drain the engine oil. Engine Oil and Oil Filter Replacement (RWD) , or Engine Oil and Oil Filter Replacement (AWD)
- Place a drain pan under the vehicle.
Automatic Transmission Fluid Pan Bolt (1) - Remove [15x]
- Automatic Transmission Fluid Pan (2) - Remove
- Automatic Transmission Fluid Pan Gasket (3) - Remove
- CAUTION:
Pull the fluid filter assembly straight out to avoid damage. Do not bend or twist the filter neck.
Automatic Transmission Fluid Filter (1) - Remove
- Automatic Transmission Fluid Filter (1) - Install
- Automatic Transmission Fluid Pan Gasket (3) - Install
- Automatic Transmission Fluid Pan (2) - Install
- Automatic Transmission Fluid Pan Bolt (1) - Install and tighten in sequence [15x] - Fastener Specifications
- Remove drain pan from under vehicle.
Windshield Wiper Arm (3) - Remove [2x]
- Using the appropriate trim tool, remove the windshield wiper arm finish cap (1) from the windshield wiper arm (3).
- Windshield Wiper Arm Nut (2) - Remove
- Grasp the outer end of the windshield wiper arm (3) and gently rock the arm back and forth to remove it from the windshield wiper transmission pivot shaft.
Air Inlet Grille Panel Extension (1) - Remove [2x]
- Apply two layers of masking tape around the top edge of the service part to prevent paint damage.
- Using a suitable plastic trim tool, carefully release the air inlet grille panel extension clips.
- Remove the air inlet grille panel extension (1) from the air inlet grille panel and upper front fender.
Remove the 2 hood rear outer air inlet seal retainer (1) from the left and right side.
- Remove the hood rear outer air inlet seal (2) from the left and right side.
Remove the 2 front compartment side sight shield retainer (1) from the left and right side.
- Remove the front compartment side sight shield (2) from the left and right side.
Air Inlet Grille Panel Retainer (1) - Remove [6x]
- Air Inlet Grille Panel (2) - Remove
- Disconnect the windshield washer nozzle hose from the windshield washer pump hose.
- Lift the front edge of the air inlet grille panel (2) and slide the panel forward from both hood hinges to remove.
Windshield Wiper System Module Shield (1) - Remove
Disconnect the windshield wiper motor electrical connector.
- Windshield Wiper System Module Bolt (1) - Remove [2x]
- Slide the windshield wiper system module (2) inboard to release the grommet from the plenum and remove the windshield wiper system module (2) from the vehicle.
Air Inlet Deflector Water Deflector Retainer (1) - Remove [2x]
Air Inlet Deflector Water Deflector (1) - Remove
Plenum Front Panel Nut (1) - Remove [3x]
- Plenum Front Panel Bolt (2) - Remove [3x]
- Disconnect the forward lamp wiring harness extension retainers as necessary.
- {If equipped} Pull the forward lamp wiring harness extension (3) out from the plenum front panel.
Plenum Front Panel Bolt (1) - Remove [4x]
- Plenum Front Panel Nut (2) - Remove [3x]
- Pull the forward lamp wiring harness extension (3) out from the plenum front panel.
Plenum Front Panel (1) - Remove
Lift up on the front of the intake manifold cover (1).
Intake Manifold Cover (1) - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @ Engine Coolant Heater Exhaust Pipe - Remove
Heater Inlet Hose Retainer (1) - Disengage
- Heater Inlet Hose (2) @ Engine Coolant Heater Exhaust Pipe - Remove
Retainer (1) - Unclip [5x]
- Engine Wiring Harness (2) - Reposition away
Engine Wiring Harness Conduit Bracket Bolt (1) - Remove
- Engine Wiring Harness Conduit Nut (2) - Remove
- Engine Wiring Harness Bracket (3) - Remove
Engine Coolant Air Bleed Pipe Bolt (1) - Remove [2x]
- Raise and support the vehicle. Lifting and Jacking the Vehicle
Rear Tire Front Air Deflector Bolt (1) - Remove [2x]
- Rear Tire Front Air Deflector- Left Side (2) - Remove
Rear Wheelhouse Liner Screw (1) - Remove
- Underbody Rear Air Deflector Plastic Nut (2) - Remove [3x]
- Underbody Rear Air Deflector Bolt (3) - Remove [3x]
- Underbody Rear Air Deflector Nut (4) - Remove [2x]
- Underbody Rear Air Deflector- Left Side (5) - Remove
Rear Tire Front Air Deflector Bolt (2) - Remove [2x]
- Rear Tire Front Air Deflector- Right Side (1) - Remove
Rear Wheelhouse Liner Screw (1) - Remove
- Underbody Rear Air Deflector Bolt (2) - Remove [3x]
- Underbody Rear Air Deflector Plastic Nut (3) - Remove [3x]
- Underbody Rear Air Deflector Nut (4) - Remove [2x]
- Underbody Rear Air Deflector- Right Side (5) - Remove
Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose Clamp (1) @ Automatic Transmission Fluid Cooling Exchanger - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Automatic Transmission Fluid Cooling Heat Exchanger Inlet Hose (2) @ Automatic Transmission Fluid Cooling Exchanger - Remove
Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose Clamp (1) @ Automatic Transmission Fluid Cooling Exchanger - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Automatic Transmission Fluid Cooling Heat Exchanger Outlet Hose (2) @ Automatic Transmission Fluid Cooling Exchanger - Remove
Transmission Fluid Cooler Pipe Nut (1) - Remove [2x]
- Transmission Fluid Cooler Pipe Bolt (2) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (3) - Remove
Transmission Fluid Cooler Pipe Seal (1) - Remove and DISCARD [2x]
- Transmission Fluid Cooler Seal (2) - Remove and DISCARD
Transmission Fluid Auxiliary Cooler Bolt (1) - Remove [2x]
Transmission Fluid Auxiliary Cooler Bracket Nut (1) - Remove
- Automatic Transmission Fluid Cooling Exchanger (2) - Remove
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Pipe (2) @ Engine Coolant Air Bleed Hose - Remove
- Lower the vehicle.
Disconnect and reposition the electrical connectors as necessary.
- The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
- The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
- Using the J-39194 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Pipe (2) @ Auxiliary Water Pump Inlet Pipe - Remove
- Remove the transmission vent hose retainer from the engine coolant air bleed pipe.
Engine Coolant Air Bleed Pipe (1) - Remove
Disconnect and reposition heated oxygen sensor electrical connector (1).
Turbocharger Heat Shield Bolt (1) - Remove [3x]
Turbocharger Heat Shield (1) - Remove
Catalytic Converter Heat Shield Bolt (1) - Remove [2x]
- Catalytic Converter Heat Shield Nut (2) - Remove
Catalytic Converter Heat Shield (1) - Remove
Exhaust Pipe Clamp (1) - Loosen
Catalytic Converter Brace Bolt (1) - Remove
- Disconnect and reposition electrical connectors as necessary.
- Raise the vehicle.
Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Remove [6x]
- Floor Panel Reinforcement (2) - Remove
Catalytic Converter Nut (1) - Remove [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Separate
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Separate
With the aid of an assistant, remove the exhaust system (1).
- Catalytic Converter Gasket (2) - Remove and DISCARD
Front Crossmember Brace Nut (1) - Remove [4x]
- Front Crossmember Brace (2) - Remove
Catalytic Converter Brace Bolt (1) - Remove
Warm Up Three-Way Catalytic Converter (1) - Remove
- Catalytic Converter Gasket (2) - Remove and DISCARD
Exhaust Pipe Clamp (1) - Remove and DISCARD
Exhaust Heat Shield Bolt (1) - Remove [6x]
- Exhaust Intermediate Underbody Heat Shield (2) - Remove
Floor Panel Number 2 Cross Bar Reinforcement Bolt (2) - Remove [4x]
- Floor Panel Number 2 Cross Bar Reinforcement (1) - Remove
Propeller Shaft Hub Clamp (1) - Remove and DISCARD
Mark (2) the relationship of the propeller shaft to the rear differential flange using a paint pen.
- Rear Propeller Shaft Nut (3) - Remove [3x]
- Rear Propeller Shaft Bolt (1) - Remove [3x]
- Support and secure the propeller shaft to a suitable hydraulic jack stand.
Propeller Shaft Bearing Support Bolt (1) - Remove [2x]
Propeller Shaft (1) - Remove
Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
- Engine Oil Cooler Coolant Inlet Hose (2) @ Engine Oil Cooler - Remove
- Thermostat Bypass Hose (3) @ Engine Oil Cooler - Remove
Engine Oil Cooler Bolt (1) - Remove [4x]
- Engine Oil Cooler (2) - Remove
- Engine Oil Cooler Seal (3) - Remove and DISCARD [2x]
- Reposition the engine oil cooler coolant inlet hose and the thermostat bypass hose aside.
Battery Negative Cable Nut (1) @ Starter Stud - Remove
- Engine Wiring Harness Retainer (2) - Disengage [2x]
- Auxiliary Generator Battery Jumper Cable (3) - Remove
Electrical Connector (1) - Disconnect
Battery Positive Cable Nut (1) @ Starter Solenoid - Remove
- Auxiliary Generator Battery Jumper Cable (2) - Remove
Starter Stud (1) - Remove
- Starter Bolt (2) - Remove [2x]
- Starter (3) - Remove
- Remove the front tire and wheel assemblies. Tire and Wheel Removal and Installation
Front Wheelhouse Liner Bolt (1) - Remove
- Engine Front Splash Shield Retainer (2) - Remove
- Engine Front Splash Shield Bolt (3) - Remove
Front Wheelhouse Liner Bolt (1) - Remove
- Engine Front Splash Shield Retainer (2) - Remove
- Engine Front Splash Shield Bolt (3) - Remove
Front Compartment Air Deflector Bolt (1) - Remove [6x]
- Front Compartment Air Deflector (2) - Remove
Repeat the following steps for all torque converter bolts (1):
- Rotate the crankshaft balancer bolt clockwise ONLY, to align the torque converter bolt with the starter opening.
- Torque Converter Bolt (1) - Remove [6x]
Automatic Transmission Range Selector Lever Cable Bolt (1) - Remove
- Remove the automatic transmission range selector lever cable (2) from the automatic transmission range selector lever cable bracket.
Slide the automatic transmission range selector locking ring (1) in the direction of the arrow to access the automatic transmission range selector cable retainer (2).
- Using a flat bladed tool, release the automatic transmission range selector cable retainer (2) then remove the automatic transmission range selector cable (3) from the automatic transmission range selector lever (4).
Disconnect the electrical connector. (1)
- Release the retainers. (2)
Disconnect the transmission vent hose retainers (1) and (2).
- Transmission Vent Hose (3) - Remove
Transmission Bolt (2) - Remove [2x]
- Transmission Stud (1) - Remove
Transmission Bolt (2) - Remove [4x]
- Transmission Stud (1) - Remove [2x]
- Support the transmission with a suitable jack.
- Strap transmission to transmission jack.
Transmission Mount Bracket Bolt (1) - Remove [4x]
Transmission Mount Bolt (1) - Remove [2x]
- Transmission Mount (2) - Remove
- Pull the transmission straight back.
- Install the J-21366 strap onto the transmission bell housing to retain the torque converter.
Remove the transmission. (1)
Install the DT-48989 Holding Fixture (2) onto the transmission.
- Install the transmission (4) with DT-48989 Holding Fixture (2) onto the DT-03289-20 Holding Fixture Base Assembly (1)
- Rotate the transmission so that the converter housing is up then secure it with the locking pin.
- Remove the DT-21366 Converter Holding Strap installed during transmission removal.
- Torque Converter (3) - Remove
Remove the two automatic transmission range selector lever cable bracket bolts (1).
- Remove the automatic transmission range selector lever cable bracket (2).
The fluid pan gasket is reusable. Inspect the gasket to determine if it may be reused. If the gasket is stuck to the case or pan, it should be replaced.
Refer to Fastener Caution .
Cap the fittings and plug the holes when removing the transmission fluid cooler pipes.
Refer to Heated Oxygen and Oxygen Sensor Caution .
The use of excessive force may damage the threads in the exhaust manifold/pipe.
When removing the propeller shaft, do not remove the propeller shaft coupler from the propeller shaft assembly. The only bolts that should be removed are those that mount each coupler to the transmission output flange, and to the rear drive axle input flange. Failure to properly remove the propeller shaft assembly may cause coupler damage, resulting in necessary replacement of the entire propeller shaft.