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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1194 (Automatic Transmission - 4L60-E/4L65-E (Service & Replacement)) >> Repair Instructions >> Transmission Replacement >> 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.
NOTE: Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
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.
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.
Fig 1: Precaution For Tilting Down Rear Of Driveline
G01973056Courtesy of GENERAL MOTORS CORP.
CAUTION: Refer to BATTERY DISCONNECT CAUTION in Cautions and Notices.
  1. Disconnect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Engine Electrical.
  2. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  3. Remove the rear tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  4. Remove the catalytic converter pipe assembly. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  5. Tie off the LH muffler assembly to the underbody to support the muffler out of the way.
    Fig 2: Catalytic Converter Pipe Assembly
    G01973057Courtesy of GENERAL MOTORS CORP.
  6. Remove the RH muffler assembly. Refer to MUFFLER REPLACEMENT -- RIGHT in Engine Exhaust.
  7. Remove the driveline tunnel closeout panel. Refer to DRIVELINE TUNNEL CLOSEOUT PANEL REPLACEMENT in Propeller Shaft.
  8. Using a flat bladed screwdriver, remove the rear bellhousing access plug.

    Important:  The following step must be performed to assure proper torque converter balance during installation.

  9. Matchmark the transmission flexplate to the transmission torque converter through the access hole in the rear bellhousing.
  10. Remove the transmission flexplate to transmission torque converter bolts. Refer to FLEXPLATE TO TORQUE CONVERTER BOLTS .
    Fig 3: Rear Bellhousing Access Plug
    G01973058Courtesy of GENERAL MOTORS CORP.
  11. Remove the two plug bolts from the front of driveline support assembly.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

    Important:  The propeller input shaft front bearing positioning bolts are intended to remain torqued to specification and in place UNTIL INSTRUCTED in the installation procedure.

    Important:  Failure to use the minimum length fastener specified will prevent proper retention of the propeller input shaft front bearing during disassembly or installation.

  12. Install two bolts, M10 - 1.5 X 55 mm, or longer, in place of the plug bolts.

    (The long bolts are located to maintain the propeller input shaft front bearing in original position during removal and installation.)

    Tighten 

    Tighten the propeller input shaft front bearing positioning bolts to 35 N.m (26 lb ft).

    Fig 4: Removing Two Plug Bolts From Front Of Driveline Support Assembly
    G01973059Courtesy of GENERAL MOTORS CORP.
  13. Using a flat bladed screwdriver, remove the engine flywheel housing access plug.
    Fig 5: Engine Flywheel Housing Access Plug
    G01973060Courtesy of GENERAL MOTORS CORP.
  14. Loosen the propeller shaft hub clamp bolt (1).

    Rotate the engine at the flywheel, if necessary for alignment.

    Fig 6: Loosening Propeller Shaft Hub Clamp Bolt
    G01973061Courtesy of GENERAL MOTORS CORP.
  15. Remove the nuts retaining the transmission shift cable bracket to the transmission.
    Fig 7: Removing Nuts Retaining Transmission Shift Cable Bracket To Transmission
    G01973062Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the transmission shift control cable from the transmission shift lever.

    Unsnap to release the cable.

  17. Position the transmission shift cable and bracket aside.
    Fig 8: Disconnecting Transmission Shift Control Cable From Transmission Shift Lever
    G01973063Courtesy of GENERAL MOTORS CORP.
  18. Remove the rear transverse spring. Refer to REAR TRANSVERSE SPRING REPLACEMENT in Rear Suspension.
  19. Support the lower control arm with a straight jack.
  20. Disconnect the outer tie rod end from the suspension knuckle. Refer to TIE ROD REPLACEMENT (OUTER END) or TIE ROD REPLACEMENT (SUSPENSION LINK) in Rear Suspension.
  21. Remove the shock absorber lower mounting bolt.
  22. Disconnect the lower ball joint from the suspension knuckle. Refer to KNUCKLE REPLACEMENT in Rear Suspension.
  23. Remove the straight jack from the control arm.
  24. Repeat steps 21 through 25 for the other side of the vehicle.
    Fig 9: Shock Absorber Lower Mounting Bolt
    G01973064Courtesy of GENERAL MOTORS CORP.
  25. Assemble the J 42055  .
  26. Install the J 42055  to a transmission jack.
  27. Position and firmly secure the J 42055  with the transmission jack to the transmission.
    Fig 10: Installing Transmission Support Fixture To Transmission Jack To Transmission Jack
    G01973065Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  29. Remove the differential to transmission lower nut.

    (Removing the nut at this time will aid in separating the differential from the transmission after the driveline has been removed from the vehicle.)

  30. Remove the transaxle mount to rear crossmember nuts.
    Fig 11: Removing Transaxle Mount To Rear Crossmember Nuts
    G01973066Courtesy of GENERAL MOTORS CORP.
  31. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
  32. Using ONLY HAND TOOLS, remove the rear suspension crossmember retaining nuts.
    Fig 12: Rear Suspension Crossmember Retaining Nuts
    G01973067Courtesy of GENERAL MOTORS CORP.
  33. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
    Fig 13: Crossmember
    G01973068Courtesy of GENERAL MOTORS CORP.
  34. Remove the transaxle mount bracket to differential bolts.
  35. Remove the transaxle mount with bracket.

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

    Fig 14: Removing Transaxle Mount With Bracket
    G01973069Courtesy of GENERAL MOTORS CORP.
  36. Using a pry bar, CAREFULLY release the axle shafts from the differential.
  37. Tie off the axle shafts to the underbody to support the shafts out of the way.

    The LH muffler assembly pipe toward the rear offers a good location to help support the LH axle shaft (1).

    Fig 15: Releasing Axle Shafts From Differential
    G01973070Courtesy of GENERAL MOTORS CORP.
  38. 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 16: Releasing Retainer Securing Wiring Harness To L-Shaped Brackets Along Driveline Support Assembly
    G01973071Courtesy of GENERAL MOTORS CORP.
  39. SLOWLY lower the driveline approximately 5 cm (2 in), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.
  40. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 17: Disconnecting Vehicle Speed Sensor (VSS) Electrical Connector
    G01973072Courtesy of GENERAL MOTORS CORP.
  41. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  42. Disconnect the wiring harness retainer clip from the top of the differential.
    Fig 18: Disconnecting Wiring Harness Retainer Clip From Top Of Differential
    G01973073Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the transmission harness 20-way connector.

    Depress both tabs on the connector and pull straight up; do not pry the connector.

    Fig 19: Disconnecting Transmission Harness 20-Way Connector
    G01973074Courtesy of GENERAL MOTORS CORP.
  44. Disconnect the park/neutral position switch electrical connectors.
  45. Remove the bolt retaining the transmission wiring harness to the LH side of the transmission case.
    Fig 20: Disconnecting Park/Neutral Position Switch Electrical Connectors
    G01973075Courtesy of GENERAL MOTORS CORP.
  46. 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.

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

  47. Release the wiring harness from the harness retainer along the top of the transmission.
  48. Check to be sure that the wiring harness is free from the driveline being removed.
    Fig 21: Lowering Driveline Approximately Height
    G01973076Courtesy of GENERAL MOTORS CORP.
  49. Disconnect the transmission oil cooler rear pipes from the junction fittings at the engine flywheel housing, then cap the pipes and plug the junction fittings to prevent contamination.
    Fig 22: Disconnecting Transmission Oil Cooler Rear Pipes From Junction Fittings At Engine Flywheel Housing
    G01973077Courtesy of GENERAL MOTORS CORP.
  50. 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.
  51. Remove the five driveline support assembly to engine flywheel housing bolts.
    Fig 23: Removing Five Driveline Support Assembly To Engine Flywheel Housing Bolts
    G01973078Courtesy of GENERAL MOTORS CORP.
  52. 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.
    Fig 24: Bending Wiring Harness Bracket Away From Driveline
    G01973079Courtesy of GENERAL MOTORS CORP.

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

  53. 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 25: Prying Driveline Loose From Engine
    G01973080Courtesy of GENERAL MOTORS CORP.
  54. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  55. 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.
  56. SLOWLY lower the driveline completely out of the vehicle.
    Fig 26: Removing Of Driveline From Vehicle
    G01973081Courtesy of GENERAL MOTORS CORP.
  57. Position the chainfall, or equivalent, of a lift device in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly.
  58. Using the lift device, raise the driveline to relieve the weight from the transmission jack.
  59. Disconnect the J 42055  from the transmission jack ONLY, the J 42055  will provide stability to the driveline components while working on a bench.
  60. Position the driveline on a workbench with the lift device still attached.
  61. Support the driveline support assembly and the differential for additional balance.
  62. Remove the lift device from the driveline.
    Fig 27: Positioning Driveline On A Workbench With Lift Device
    G01973082Courtesy of GENERAL MOTORS CORP.
  63. Disconnect the transmission oil cooler rear pipes from the fittings on the transmission, then cap the pipes and plug the transmission fittings to prevent contamination.
    Fig 28: Disconnecting Transmission Oil Cooler Rear Pipes From Fittings On Transmission
    G01973083Courtesy of GENERAL MOTORS CORP.
  64. Remove the transmission to driveline support assembly bolts/studs.
  65. 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.
  66. Slowly slide the driveline support assembly away from the transmission while supporting the transmission torque converter.
  67. Using a strap positioned from side to side, secure the transmission torque converter to the transmission.
    Fig 29: Removing Transmission To Driveline Support Assembly Bolts/Studs
    G01973084Courtesy of GENERAL MOTORS CORP.
  68. Remove the differential to transmission bolts and nuts.

    Important:  Use care when separating the differential from the transmission to not damage the transmission output shaft seal in the differential plate.

  69. SLOWLY slide the differential from the transmission.
    Fig 30: Removing Differential To Transmission Bolts & Nuts
    G01973085Courtesy of GENERAL MOTORS CORP.
  70. Remove the differential plate from the differential.
  71. Remove the transmission from the J 42055  , if necessary.
    Fig 31: Removing Differential Plate From Differential
    G01973086Courtesy of GENERAL MOTORS CORP.
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