LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1186 (Drive Shaft) >> Repair Instructions >> Driveline Support Assembly Replacement (Manual Transmission) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: When tilting down the rear of the driveline, insert a putty knife or similar tool between the shift control bracket on the driveline support assembly and the brake pipe retainer on the driveline tunnel wall to prevent damage.
NOTE: Ensure that the clutch hydraulic hoses are positioned away from nearby vehicle components or vehicle damage may result.
  1. Slowly slide the driveline support assembly to the transmission, while guiding the shift rod through the opening in the driveline support assembly.
    Fig 1: Sliding Driveline Support Assembly To Transmission
    G01419707Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .
  2. Install the transmission to driveline support assembly bolts/studs.
    Fig 2: Installing Transmission To Driveline Support Assembly Bolts/Studs
    G01419708Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the transmission to driveline support assembly bolts/studs to 50 N.m (37 lb ft).

  3. Install the rear exhaust hangers to the driveline support assembly.
  4. Install the rear exhaust hanger mounting bolts.
    Fig 3: Installing Rear Exhaust Hanger Mounting Bolts
    G01419709Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the rear exhaust hanger mounting bolts to 50 N.m (37 lb ft).

  5. Install the clutch actuator cylinder to the driveline support assembly.
    Fig 4: Installing Clutch Actuator Cylinder To Driveline Support Assembly
    G01419710Courtesy of GENERAL MOTORS CORP.
  6. Install the clutch actuator cylinder mounting bolts.

    Tighten 

    Tighten the clutch actuator cylinder mounting bolts to 12 N.m (106 lb in).

  7. Loosely install a rubber band onto the transmission shift rod and position just behind the shift rod clamp.
    Fig 5: Installing Rubber Band Onto Transmission Shift Rod
    G01419711Courtesy of GENERAL MOTORS CORP.

    The rubber band will be used to aid in installing the shift control rod after the driveline has been installed.

  8. Using a piece of masking tape, or similar tape which can be easily broken, affix the transmission shift rod to the driveline support assembly and position the rod just to the outside of the mounting boss used for the shift control.

    The tape is intended to keep the shift control rod in position, and to aid in shift control rod installation.

  9. Position the chainfall, or equivalent lifting device, in a way which will protect the rear exhaust hangers located on the driveline support assembly.

    Important:  The aid of an assistant will be necessary for the following steps until the driveline is installed into the vehicle.

  10. Using the lifting device, raise the driveline off the workbench and position the driveline with the J 42055  onto a transmission jack.
    Fig 6: Positioning Driveline Onto Transmission Jack
    G01419712Courtesy of GENERAL MOTORS CORP.
  11. Connect the J 42055  to the transmission jack.
  12. Remove the lifting device from the driveline.
  13. Position the driveline under the vehicle.
  14. Begin to raise the driveline at the approximate angle used during removal.
  15. Position the wiring harness along the driveline support assembly and LOOSELY install the harness into the harness retaining slots.
  16. Have an assistant guide the front of the driveline so the propeller input shaft is just to the rear of the engine flywheel housing, then raise the driveline to the PROPER HEIGHT and the PROPER ANGLE to install to the engine.
  17. Have an assistant begin to insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle of the driveline; if necessary, use a screwdriver to rotate the shaft slightly to bring the splines into alignment.
    Fig 7: Inserting Propeller Input Shaft Into Clutch Driven Plate Hub
    G01419713Courtesy of GENERAL MOTORS CORP.
  18. Insert a putty knife, or similar tool, between the edge of the shifter bracket on the side of the driveline support assembly and the brake pipe retainer on the wall of the driveline tunnel.
    Fig 8: Inserting Putty Knife
    G01419714Courtesy of GENERAL MOTORS CORP.
  19. SLOWLY seat the driveline to the engine flywheel housing while maintaining the proper angle of the driveline.
  20. Reposition the wiring harness bracket from near the driveline tunnel wall to align with the appropriate driveline support assembly bolt hole.
    Fig 9: Seating Driveline To Engine Flywheel Housing
    G01419715Courtesy of GENERAL MOTORS CORP.
  21. Install the five driveline support assembly to engine flywheel housing bolts.
    Fig 10: Installing Driveline Support Assembly To Engine Flywheel Housing Bolts
    G01419716Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the driveline support assembly to engine flywheel housing bolts to 50 N.m (37 lb ft).

  22. Install the wiring harness to the wiring harness retainer along the top of the transmission.
  23. SLOWLY raise the driveline to approximately 51 mm (2.0 in) BELOW the final installed height.
  24. Connect the transmission fluid temperature sensor electrical connector, if equipped.
    Fig 11: Connecting Transmission Fluid Temperature Sensor Electrical Connector
    G01419717Courtesy of GENERAL MOTORS CORP.
  25. Connect the gear select (skip shift) solenoid electrical connector.
    Fig 12: Connecting Gear Select (Skip Shift) Solenoid Electrical Connector
    G01419718Courtesy of GENERAL MOTORS CORP.
  26. Connect the reverse lockout solenoid electrical connector.
    Fig 13: Connecting Reverse Lockout Solenoid Electrical Connector
    G01419719Courtesy of GENERAL MOTORS CORP.
  27. Connect the backup lamp switch electrical connector.
    Fig 14: Connecting Backup Lamp Switch Electrical Connector
    G01419720Courtesy of GENERAL MOTORS CORP.
  28. Connect the wiring harness clip to the top of the differential.
    Fig 15: Connecting Wiring Harness Clip To Top Of differential
    G01419721Courtesy of GENERAL MOTORS CORP.
  29. Connect the wiring harness retainer to the stud at the differential rear cover.
  30. Connect the vehicle speed sensor (VSS) electrical connector.
    Fig 16: Connecting Vehicle Speed Sensor (VSS) Electrical Connector
    G01419722Courtesy of GENERAL MOTORS CORP.
  31. Slowly raise the driveline to final installation height.
  32. Remove the putty knife, if still in position.
  33. Remove the jack which supported the rear of the engine.
  34. Remove the tie-off retainers from the axle shafts.
  35. CAREFULLY align and seat the wheel drive shafts to the differential.
  36. Install the transaxle mount with bracket to the differential.
    Fig 17: Installing Transaxle Mount With Bracket To Differential
    G01419723Courtesy of GENERAL MOTORS CORP.
  37. Install the transaxle mount bracket to differential bolts.

    Tighten 

    Tighten the transaxle mount bracket to differential bolts to 50 N.m (37 lb ft).

  38. With the aid of an assistant, begin to raise the rear suspension crossmember (still firmly attached to a transmission jack), until it contacts the vehicle frame rails.
  39. Guide the rear suspension crossmember alignment pins into the alignment holes in the vehicle frame rails, and guide the transaxle mount studs into the mounting holes in the crossmember, then raise the crossmember until it contacts the vehicle frame rails.
    Fig 18: Raising Rear Suspension Crossmember
    G01419724Courtesy of GENERAL MOTORS CORP.
  40. Using ONLY HAND TOOLS, install NEW rear suspension crossmember mounting nuts.
    Fig 19: Installing Rear Suspension Crossmember Mounting Nuts
    G01419725Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the rear suspension crossmember mounting nuts to 110 N.m (81 lb ft).

  41. Remove the transmission jack from the rear suspension crossmember.
  42. Release the J 42055  from the transmission, then remove the J 42055  and transmission jack.
  43. Install the transaxle mount to rear suspension crossmember nuts.
    Fig 20: Installing Transaxle Mount To Rear Suspension Crossmember Nuts
    G01419726Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the transaxle mount to rear suspension crossmember nuts to 50 N.m (37 lb ft).

  44. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
  45. Support the lower control arm with a straight jack.
  46. Connect the lower ball joint to the suspension knuckle. Refer to KNUCKLE REPLACEMENT .
  47. Install the shock absorber lower mounting bolt.
    Fig 21: Installing Shock Absorber Lower Mounting Bolt
    G01419727Courtesy of GENERAL MOTORS CORP.

    Tighten 

    Tighten the rear shock absorber lower mounting bolt to 220 N.m (162 lb ft).

  48. Connect the outer tie rod end to the suspension knuckle. Refer to TIE ROD REPLACEMENT (OUTER END) or TIE ROD REPLACEMENT (SUSPENSION LINK) .
  49. Remove the straight jack from the suspension control arm.
  50. Repeat steps 45 through 49 for the other side of the vehicle.
  51. Install the rear transverse spring. Refer to REAR TRANSVERSE SPRING REPLACEMENT .
  52. Carefully pull the wiring harness down into the L-shaped brackets along the driveline support assembly, align the harness retainer (locator) (1) to the hole in the forward bracket, then secure in place.
    Fig 22: Aligning Harness Retainer To Hole In Forward Bracket
    G01419728Courtesy of GENERAL MOTORS CORP.

    Important:  DO NOT rely on an audible click or a visual verification of the clutch hydraulic hose quick connect fitting connection.

  53. Connect the clutch actuator cylinder hose to the clutch master cylinder hose.
    Fig 23: Connecting Clutch Actuator Cylinder Hose To Clutch Master Cylinder Hose
    G01419729Courtesy of GENERAL MOTORS CORP.

    Push together the clutch hydraulic hose quick connect fittings, then pull back on the fittings to verify engagement.

  54. Check the clutch hydraulic hoses for twists or kinks.
  55. Install the clutch actuator cylinder hose to the hose retaining clip, at the rear of the engine.
    Fig 24: Installing Clutch Actuator Cylinder Hose To Hose Retaining Clip
    G01419730Courtesy of GENERAL MOTORS CORP.
  56. Install the driveline tunnel closeout panel. Refer to DRIVELINE TUNNEL CLOSEOUT PANEL REPLACEMENT   . 
  57. Remove the tie-off retainers from the muffler assemblies.
  58. Install the catalytic converters. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  59. Install the rear tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  60. Lower the vehicle.
  61. Connect the clutch master cylinder pushrod to the clutch pedal.
    Fig 25: Connecting Clutch Master Cylinder Pushrod To Clutch Pedal
    G01419731Courtesy of GENERAL MOTORS CORP.
  62. Install the clutch master cylinder pushrod retainer.
  63. Install the left I/P lower insulator panel. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - LEFT in Instrument Panel, Gauges and Console.
  64. Grasp the transmission shift rod and pull up to break the masking tape installed earlier to maintain position during installation.
  65. Stretch the rubber band, while still installed onto the transmission shift rod, over the rear stud on top of the driveline tunnel to aid in shift control installation.
    Fig 26: Maintaining Position During Transmission Shift Rod Installation
    G01419732Courtesy of GENERAL MOTORS CORP.
  66. Install the shift control assembly. Refer to SHIFT CONTROL ASSEMBLY REPLACEMENT in Manual Transmission.
  67. Break and remove the rubber band.
  68. Install the shift control closeout boot.
    Fig 27: Installing Shift Control Closeout Boot
    G01419733Courtesy of GENERAL MOTORS CORP.

    Check that the closeout boot fully seats to the shift control lever seal and the base of the shift control assembly (1).

  69. Install the shift control closeout boot retaining nuts.

    Tighten 

    Tighten the shift control closeout boot retaining nuts to 12 N.m (106 lb in).

  70. Install the I/P accessory trim plate. Refer to TRIM PLATE REPLACEMENT - INSTRUMENT PANEL (I/P) ACCESSORY in Instrument Panel, Gauges and Console.
  71. Install the shift control boot over the shift control lever.
    Fig 28: Installing Shift Control Boot Over Shift Control Lever
    G01419734Courtesy of GENERAL MOTORS CORP.
  72. Align the shift control boot to the I/P accessory trim plate opening, then press to lock the boot retaining tabs.
  73. Adjust the shape of the boot for appearance, if necessary.
    Fig 29: Aligning Shift Control Boot To I/P Accessory Trim Plate Opening
    G01419735Courtesy of GENERAL MOTORS CORP.
  74. Screw the shift control knob onto the shift control lever until the knob bottoms out.
    Fig 30: Installing Shift Control Knob
    G01419736Courtesy of GENERAL MOTORS CORP.
  75. Unscrew the shift control knob just enough to align the retainer slot with the slot on the shift control lever.
    Fig 31: Installing Shift Control Knob Retainer Into Slots
    G01419737Courtesy of GENERAL MOTORS CORP.
  76. Install the shift control knob retainer (1) into the slots and seat fully.
  77. Install the shift control knob button.
  78. Install the console. Refer to CONSOLE REPLACEMENT in Instrument Panel, Gauges and Console.
  79. Connect the negative battery cable.

    Tighten 

    Tighten the negative battery cable bolt to 15 N.m (11 lb ft).

  80. Program the transmitters. Refer to TRANSMITTER PROGRAMMING in Keyless Entry.
  81. Bleed the clutch hydraulic system. Refer to HYDRAULIC CLUTCH BLEEDING in Clutch.
scientia non olet · About LEMON Manuals