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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 >> Removal Procedure

Removal 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. Shift the transmission into 3rd or 4th gear.
  2. Remove the shift lever. Refer to Shift Lever Assembly Replacement   . 
  3. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE .
    IMPORTANT: The clutch actuator cylinder hose can remain attached to the clutch actuator. Disconnecting the hose from the clutch actuator cylinder will cause the fluid to drain from the hydraulic system.
  4. Drain the transmission fluid.
    Fig 1: Verifying Clutch Actuator Cylinder Hose Is Attached To Clutch Actuator
    G01953197Courtesy of GENERAL MOTORS CORP.
  5. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - ONE PIECE or PROPELLER SHAFT REPLACEMENT - TWO PIECE .
  6. If equipped with 4 wheel drive (4WD), remove 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).
  7. Disconnect the clutch actuator cylinder hydraulic hose quick connect at the master cylinder.
  8. Disconnect the clutch actuator cylinder line retaining clips.
  9. If equipped with a 6.6L engine, disconnect the following electrical connectors:
    • Power take-off (PTO) (2), if connected
    • Backup lamp switch (3)
    • Vehicle speed sensor (VSS) (4)
  10. Remove the engine harness clips (1) from the fuel feed/return bracket.
  11. Remove the PTO connector from the fuel feed/return bracket.
  12. Reposition the harness.
  13. Remove the fuel lines from the fuel feed/return brackets.
    Fig 2: Disconnecting Electrical Connectors (6.6L)
    G01953198Courtesy of GENERAL MOTORS CORP.
  14. If equipped with a 8.1L engine, disconnect the following electrical connectors:
    • Power take-off (PTO) (2), if connected
    • Oxygen sensors (1, 3)
    • Backup lamp switch (4)
    • VSS (5)
  15. Remove the engine harness clips (6) from the fuel feed/return brackets.
  16. Remove the PTO connector from the fuel feed/return bracket.
  17. Remove the oxygen sensors connectors (1, 3) from the fuel feed/return hose clip and transmission bracket.
  18. Reposition the harness.
  19. Remove the fuel lines from the fuel feed/return brackets.
    Fig 3: Disconnecting Electrical Connectors (8.1L)
    G01953199Courtesy of GENERAL MOTORS CORP.
  20. If equipped with 4WD, remove the vent hose clip from the bracket.
  21. Remove the vent hose clip nut and clip.
    Fig 4: Removing Vent Hose Clip Nut & Clip (4Wd)
    G01953200Courtesy of GENERAL MOTORS CORP.
  22. If equipped with 4WD, remove the vent hose clip (1) from the fuel feed/return bracket.
  23. Remove the starter. Refer to STARTER MOTOR .
    Fig 5: Removing Vent Hose Clip From Fuel Feed/Return Bracket (4WD)
    G01953201Courtesy of GENERAL MOTORS CORP.
  24. Remove the exhaust pipe hanger bracket bolts and bracket.
  25. Support the transmission with a suitable transmission jack.
  26. Remove the transmission support.
    Fig 6: Removing Exhaust Pipe Hanger Bracket & Bolts
    G01953202Courtesy of GENERAL MOTORS CORP.
  27. If equipped with a 6.6L engine, remove the transmission bolts/studs.
  28. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  29. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  30. Remove the insulator from the top of the transmission.
    Fig 7: Removing Transmission Bolts/Studs (6.6L)
    G01953203Courtesy of GENERAL MOTORS CORP.
  31. If equipped with a 8.1L engine, remove the transmission studs.
  32. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  33. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  34. Remove the insulator from the top of the transmission.
    Fig 8: Removing Transmission & Studs (8.1L)
    G01953204Courtesy of GENERAL MOTORS CORP.
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