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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) >> Removal Procedure

Removal 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.

Caution: Refer to BATTERY DISCONNECT CAUTION .

NOTE: When tilting down the rear of the driveline, observe the clearance between the rear of the engine and the composite dash panel. Do not allow the engine to rest unsupported against the composite dash panel, or vehicle damage may result.
Fig 1: Observing Clearance Between Rear Of Engine & Composite Dash Panel
G01419673Courtesy of GENERAL MOTORS CORP.
NOTE: When lowering and removing the rear of the driveline, observe the clearance between the rear of the transaxle assembly and the underbody to prevent damage.
  1. Disconnect the negative battery cable.
  2. Remove the console. Refer to CONSOLE REPLACEMENT in Instrument Panel, Gauges and Console.
  3. Carefully pry off the shift control knob button.
  4. Pry the shift control knob retainer out of the slots and remove the retainer.
    Fig 2: Prying Off Shift Control Knob Button
    G01419674Courtesy of GENERAL MOTORS CORP.
  5. Unscrew the shift control knob.
    Fig 3: Unscrewing Shift Control Knob
    G01419675Courtesy of GENERAL MOTORS CORP.
  6. Grasp the sides of the shift control boot and apply light pressure in toward the shift control lever to begin to release the shift boot retaining tabs from the I/P accessory trim plate.
  7. Using light pressure, continue to release the remaining boot retaining tabs.
    Fig 4: Releasing Shift Boot Retaining Tabs From I/P Accessory Trim Plate
    G01419676Courtesy of GENERAL MOTORS CORP.
  8. Lift the boot away from the trim plate and remove the boot.
    Fig 5: Removing Boot
    G01419677Courtesy of GENERAL MOTORS CORP.
  9. Remove the I/P accessory trim plate. Refer to TRIM PLATE REPLACEMENT - INSTRUMENT PANEL (I/P) ACCESSORY in Instrument Panel, Gauges and Console.
  10. Remove the shift control closeout boot retaining nuts.
    Fig 6: Removing Shift Control Closeout Boot
    G01419678Courtesy of GENERAL MOTORS CORP.
  11. Remove the shift control closeout boot.
  12. Remove the shift control assembly. Refer to SHIFT CONTROL ASSEMBLY REPLACEMENT in Manual Transmission - MM6.
  13. Remove the left I/P lower insulator panel. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - LEFT in Instrument Panel, Gauges and Console.
  14. Remove the clutch master cylinder pushrod retainer.
  15. Disconnect the clutch master cylinder pushrod from the clutch pedal.
    Fig 7: Disconnecting Clutch Master Cylinder Pushrod From Clutch Pedal
    G01419679Courtesy of GENERAL MOTORS CORP.
  16. Raise and support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
  17. Remove the clutch actuator cylinder hose from the hose retaining clip, at the rear of the engine.
    Fig 8: Removing Clutch Actuator Cylinder Hose From Hose Retaining Clip
    G01419680Courtesy of GENERAL MOTORS CORP.
  18. Using the J 36221,  depress the white circular release ring on the actuator cylinder hose and simultaneously pull lightly on the master cylinder hose to disconnect.
    Fig 9: Disconnecting Clutch Actuator Cylinder Hose
    G01419681Courtesy of GENERAL MOTORS CORP.
  19. Protect both hose coupling ends from dirt and damage.
  20. Remove the rear tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  21. Remove the catalytic converters. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  22. Tie off the muffler assemblies to the underbody to support out of the way.
    Fig 10: Tying Muffler Assemblies To Underbody
    G01419682Courtesy of GENERAL MOTORS CORP.
  23. Remove the driveline tunnel closeout panel. Refer to DRIVELINE TUNNEL CLOSEOUT PANEL REPLACEMENT  .
  24. Remove the rear transverse spring. Refer to REAR TRANSVERSE SPRING REPLACEMENT .
  25. Support the lower control arm with a straight jack.
  26. Disconnect the outer tie rod end from the suspension knuckle. Refer to TIE ROD REPLACEMENT (OUTER END) or TIE ROD REPLACEMENT (SUSPENSION LINK) .
  27. Remove the shock absorber lower mounting bolt.
    Fig 11: Removing Shock Absorber Lower Mounting Bolt
    G01419683Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the lower ball joint from the suspension knuckle. Refer to KNUCKLE REPLACEMENT .
  29. Remove the straight jack from the control arm.
  30. Repeat steps 25 through 29 for the other side of the vehicle.
  31. Assemble the J 42055. 
  32. Install the J 42055  to a transmission jack.
  33. Position and firmly secure the J 42055  with the transmission jack to the transmission.
    Fig 12: Positioning J 42055
    G01419684Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  35. Remove the transaxle mount to rear crossmember nuts.
    Fig 13: Removing transaxle mount to rear crossmember nuts
    G01419685Courtesy of GENERAL MOTORS CORP.
  36. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
    Fig 14: Positioning Transmission Jack Under Rear Suspension Crossmember
    G01419686Courtesy of GENERAL MOTORS CORP.
  37. Using ONLY HAND TOOLS, remove the rear suspension crossmember retaining nuts.
  38. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
    Fig 15: Lowering Rear Suspension Crossmember Away From Vehicle Frame Rails
    G01419687Courtesy of GENERAL MOTORS CORP.
  39. Remove the transaxle mount bracket to differential bolts.
    Fig 16: Removing Transaxle Mount Bracket
    G01419688Courtesy of GENERAL MOTORS CORP.
  40. Remove the transaxle mount with bracket.

    Removing the transaxle mount will allow for greater stability on a workbench after the driveline is removed.

  41. Using a pry bar, CAREFULLY release the wheel drive shafts from the differential.
  42. Tie off the wheel drive shafts (1) to the underbody to support out of the way.

    The muffler assembly pipes toward the rear offer a good location to help support the wheel drive shafts (1).

    Fig 17: Tying Wheel Drive Shafts To Underbody
    G01419689Courtesy of GENERAL MOTORS CORP.
  43. Release the retainer (1) securing (and positioning) the wiring harness to the L-shaped brackets along the driveline support assembly, then slide the harness up out of the brackets and position out of the way.
    Fig 18: Releasing retainer securing wiring harness
    G01419690Courtesy of GENERAL MOTORS CORP.
  44. SLOWLY lower the driveline approximately 51 mm (2 in), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.
  45. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 19: Disconnecting Vehicle Speed Sensor (VSS) Electrical Connector
    G01419691Courtesy of GENERAL MOTORS CORP.
  46. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  47. Disconnect the wiring harness retainer clip from the top of the differential.
    Fig 20: Disconnecting Wiring Harness Retainer Clip From Top Of The Differential
    G01419692Courtesy of GENERAL MOTORS CORP.
  48. Disconnect the backup lamp switch electrical connector.
    Fig 21: Disconnecting Backup Lamp Switch Electrical Connector
    G01419693Courtesy of GENERAL MOTORS CORP.
  49. Disconnect the reverse lockout solenoid electrical connector.
    Fig 22: Disconnecting Reverse Lockout Solenoid Electrical Connector
    G01419694Courtesy of GENERAL MOTORS CORP.
  50. Disconnect the gear select (skip shift) solenoid electrical connector.
    Fig 23: Disconnecting Gear Select (Skip Shift) Solenoid Electrical Connector
    G01419695Courtesy of GENERAL MOTORS CORP.
  51. Disconnect the transmission fluid temperature sensor electrical connector, if equipped.
    Fig 24: Disconnecting Transmission Fluid Temperature Sensor Electrical Connector
    G01419696Courtesy of GENERAL MOTORS CORP.
  52. 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 25: Inserting a putty knife between edge of shifter bracket and brake pipe retainer
    G01419697Courtesy of GENERAL MOTORS CORP.
  53. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt, and observe the relationship between the top rear of the differential and the lowest part of the rear compartment panel floor (the center storage compartment between the frame rails); the differential should not be lowered more than approximately EVEN with the specified body point of reference.
    Fig 26: Lowering Driveline
    G01419698Courtesy of GENERAL MOTORS CORP.

    The engine positive crankcase ventilation (PCV) pipes which route along the rear of the engine intake manifold [LS1 only] will likely contact the dash panel.

  54. Release the wiring harness from the harness retainer along the top of the transmission.
  55. Check to be sure that the wiring harness is free from the driveline being removed.
  56. Using a block of wood to protect the engine oil pan, place a straight jack under the rear of the engine oil pan to support the engine from stressing the composite dash panel.
  57. Remove the five driveline support assembly to engine flywheel housing bolts.
    Fig 27: Removing Driveline Support Assembly To Engine Flywheel Housing Bolts
    G01419699Courtesy of GENERAL MOTORS CORP.
  58. Carefully bend the wiring harness bracket away from the driveline toward the driveline tunnel wall in order to make a clear removal path for the driveline.

    Important:  The aid of an assistant will be necessary for the remaining steps.

  59. Have an assistant insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the engine flywheel housing, then begin to pry the driveline loose from the engine.
    Fig 28: Prying Driveline Loose
    G01419700Courtesy of GENERAL MOTORS CORP.
  60. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  61. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt and pulling the driveline away from the engine UNTIL the propeller input shaft at the front of the driveline support assembly just clears the engine flywheel housing.
    Fig 29: Pulling Driveline Away From Engine
    G01419701Courtesy of GENERAL MOTORS CORP.
  62. SLOWLY lower the driveline completely out of the vehicle.
  63. Position the chainfall, or equivalent lifting device, in a way which will protect the rear exhaust hangers located on the driveline support assembly.
  64. Using the lifting device, raise the driveline to relieve the weight from the transmission jack.
    Fig 30: Raising Driveline
    G01419702Courtesy of GENERAL MOTORS CORP.
  65. Disconnect the J 42055  from the transmission jack ONLY; the J 42055  will provide stability to the driveline components while working on a bench.
  66. Position the driveline on a workbench with the lifting device still attached.
  67. Support the driveline support assembly and the differential for additional balance.
  68. Remove the lifting device from the driveline.
  69. Remove the clutch actuator cylinder mounting bolts.
  70. Remove the clutch actuator cylinder from the driveline support assembly.
    Fig 31: Removing Clutch Actuator Cylinder
    G01419703Courtesy of GENERAL MOTORS CORP.
  71. Remove the rear exhaust hanger mounting bolts.
    Fig 32: Removing Rear Exhaust Hanger Mounting Bolts
    G01419704Courtesy of GENERAL MOTORS CORP.
  72. Remove the rear exhaust hangers from the driveline support assembly.
  73. Remove the transmission to driveline support assembly bolts/studs.
    Fig 33: Removing Transmission To Driveline Support Assembly Bolts/Studs
    G01419705Courtesy of GENERAL MOTORS CORP.
  74. Insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the transmission, then begin to pry the driveline support assembly loose from the transmission.
  75. Slowly slide the driveline support assembly away from the transmission while guiding the transmission shift rod through the opening in the driveline support assembly.
    Fig 34: Sliding Driveline Support Assembly Away From Transmission
    G01419706Courtesy of GENERAL MOTORS CORP.
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