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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1624 (Manual Transmission - ZF S6-650) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Sierra, 2003 GMC Cab & Chassis Sierra, 2003 Chevrolet Silverado, and 2003 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the insulator to the top of the transmission.
  2. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
  3. Rotate the transmission clockwise onto the clutch hub splines.
  4. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
    NOTE: Refer to FASTENER NOTICE .
  5. If equipped with a 8.1L engine, install the transmission studs.

    Tighten 

    Tighten the studs to 50 N.m (37 lb ft).

    Fig 1: Installing Transmission Studs (8.1L)
    G01953205Courtesy of GENERAL MOTORS CORP.
  6. Install the insulator to the top of the transmission.
  7. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
  8. Rotate the transmission clockwise onto the clutch hub splines.
  9. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
  10. If equipped with a 6.6L engine, install the transmission bolts/studs.

    Tighten 

    Tighten the bolts/studs to 50 N.m (37 lb ft).

  11. Install the transmission support.
  12. Remove the transmission jack.
    Fig 2: Installing Transmission Bolts/Studs (6.6L)
    G01953206Courtesy of GENERAL MOTORS CORP.
  13. Install the exhaust pipe hanger bracket and bolts.

    Tighten 

    Tighten the bolts to 12 N.m (106 lb in).

  14. Install the starter. Refer to STARTER MOTOR .
    Fig 3: Installing Exhaust Pipe Hanger Bracket & Bolts
    G01953207Courtesy of GENERAL MOTORS CORP.
  15. If equipped with 4WD, install the vent hose clip (1) to the fuel feed/return bracket.
    Fig 4: Installing Vent Hose Clip (4WD)
    G01953208Courtesy of GENERAL MOTORS CORP.
  16. Install the vent hose clip and nut.

    Tighten 

    Tighten the nut to 25 N.m (18 lb ft).

  17. If equipped with 4WD, install the vent hose clip to the bracket.
    Fig 5: Installing Vent Hose Clip & Nut
    G01953209Courtesy of GENERAL MOTORS CORP.
  18. Install the fuel lines to the fuel feed/return brackets.
  19. Position the harness.
  20. Install the oxygen sensors connectors (1, 3) to the fuel feed/return hose clip and transmission bracket.
  21. Install the PTO connector to the fuel feed/return bracket.
  22. Install the engine harness clips (6) to the fuel feed/return brackets.
  23. If equipped with a 8.1L engine, connect the following electrical connectors:
    • PTO (2), if connected
    • Oxygen sensors (1, 3)
    • Backup lamp switch (4)
    • VSS (5)
      Fig 6: Connecting Electrical Connectors (8.1L)
      G01953210Courtesy of GENERAL MOTORS CORP.
  24. Install the fuel lines to the fuel feed/return brackets.
  25. Position the harness.
  26. Install the PTO connector to the fuel feed/return bracket.
  27. Install the engine harness clips (1) to the fuel feed/return brackets.
  28. If equipped with a 6.6L engine, connect the following electrical connectors:
    • PTO (2), if connected
    • Backup lamp switch (3)
    • VSS (4)
      Fig 7: Connecting Electrical Connectors (6.6L)
      G01953211Courtesy of GENERAL MOTORS CORP.
  29. Connect the clutch actuator cylinder line retaining clips.
    IMPORTANT: Improper connection may cause the quick connect from locking properly. Before pushing in the clutch pedal fully, check with light pressure. If pedal is hard recheck the connection.
  30. Connect the clutch actuator cylinder hydraulic hose quick connect from the master cylinder.
  31. If equipped with 4WD, install the transfer case. Refer to TRANSFER CASE ASSEMBLY REPLACEMENT for NVG263-NP1 (Selectable) or TRANSFER CASE ASSEMBLY REPLACEMENT for Transfer Case-NVG261-NP2 (Two Speed Manual).
  32. If vehicle is a 2WD, install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - ONE PIECE or PROPELLER SHAFT REPLACEMENT - TWO PIECE .
  33. Lower the vehicle.
  34. Install the shift lever. Refer to Shift Lever Assembly Replacement   . 
  35. Fill the transmission with fluid.
  36. Bleed the clutch hydraulic system, if necessary. Refer to HYDRAULIC CLUTCH BLEEDING .
    37. Fig 8: Connecting Clutch Actuator Cylinder Line Retaining Clips
    G01953212Courtesy of GENERAL MOTORS CORP.
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