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Installation (Automatic Transmission)

WARNING: This page is about a different car, the 2003 Chevrolet Corvette and 2002 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Manufacturer recommends flushing transmission oil cooler when servicing driveline support assembly. See OIL COOLER FLUSHING under LUBRICATION in appropriate SERVING A/T article in AUTOMATIC TRANSMISSIONS.
  1. Install the differential plate to the transmission, use care not to damage the transmission output seal in the rear of the plate. See Fig 1. Position the square-lip differential plate seal flush with the transmission case.
    Fig 1: Installing Differential Plate & Seal
    G00249997Courtesy of GENERAL MOTORS CORP.
  2. Slowly slide the differential to the transmission. Install the differential-to-transmission bolts and nuts. See Figure. Tighten the differential-to-transmission bolts and nuts to specification. See TORQUE SPECIFICATIONS .
  3. Position the chainfall, or equivalent lifting device, in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly. Using the lifting device, raise the driveline off the workbench and position the driveline with the Transmission Support Fixture (J-42055) onto a transmission jack. Connect the Transmission Support Fixture to the transmission jack.
  4. Remove the lifting device from the driveline. Position the driveline under the vehicle. Begin to raise the driveline at the approximate angle used during removal. Position the wiring harness along the driveline support assembly and loosely install the harness into the harness retaining slots. 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.
  5. Have an assistant begin to insert the propeller input shaft into the propeller shaft 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. Slowly seat the driveline to the engine flywheel housing while maintaining the proper angle of the driveline.
  6. Reposition the wiring harness bracket from near the driveline tunnel wall to align with the appropriate driveline support assembly bolt hole. Install the driveline support assembly-to-engine flywheel housing bolts. Tighten the driveline support assembly-to-engine flywheel housing bolts to specification. See TORQUE SPECIFICATIONS . Install the wiring harness to the wiring harness retainer along the top of the transmission. Slowly raise the driveline to approximately 2.0" (50 mm) below the final installed height.
  7. Remove the caps from the transmission oil cooler rear pipes and remove the plugs from the junction fittings at the engine flywheel housing. Align, start and hand-tighten the transmission oil cooler rear pipe-to-junction fittings at the engine flywheel housing. Tighten the transmission oil cooler rear pipe-to-junction fittings at engine flywheel housing to specification. See TORQUE SPECIFICATIONS .
  8. Install the transmission wiring harness-to-left side transmission case retaining bolt and tighten to specification. See Figure. Connect the Park/Neutral Position (PNP) switch electrical connectors.
  9. Connect the transmission harness 20-pin connector. See Figure. Align the arrows on each half of the connector and insert straight down. Connect the wiring harness clip to the top of the differential. See Figure.
  10. Connect the wiring harness retainer to the stud at the differential rear cover. Connect the vehicle speed sensor (VSS) electrical connector. See Figure.
  11. Slowly raise the driveline to final installation height. Remove the jack which supported the engine. Remove the tie-off retainers from the axle shafts. Carefully align and seat the axle shafts to the differential.
  12. Install the transaxle mount and bracket to the differential. See Figure. Install the transaxle mount bracket-to-differential bolts. Tighten the transaxle mount bracket-to-differential bolts to specification. See TORQUE SPECIFICATIONS .
  13. With the aid of an assistant, begin to raise the rear suspension crossmember (still firmly attached to a transmission jack), to the vehicle frame rails. 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 to seat to the frame rails.
  14. Using only hand tools, install NEW rear suspension crossmember mounting nuts and tighten to specification. See TORQUE SPECIFICATIONS . Remove the transmission jack from the rear suspension crossmember. Release the Transmission Support Fixture from the transmission, then remove the Transmission Support Fixture and transmission jack.
  15. Install the transmission mount-to-rear suspension crossmember nuts. Tighten the transmission mount-to-rear suspension crossmember nuts to specification. Install the differential-to-transmission lower nut. Tighten the differential-to-transmission lower nut to specification. Connect the wiring harness and brake pipe clip retainers to the rear suspension crossmember.
  16. Support the lower control arms with a straight jack. Connect the lower ball joints to the suspension knuckles. It may be necessary to use an allen wrench to keep the ball joint studs from spinning while tightening the ball joint stud nuts. Tighten lower control arm ball joint stud nuts to specification in 3 steps. See TORQUE SPECIFICATIONS .
  17. Install the shock absorber lower mounting bolts and tighten to specification. Connect the outer tie rod ends to the suspension knuckles. Tighten outer tie rod end nuts to specification in 3 steps. See TORQUE SPECIFICATIONS .
  18. Remove the straight jack from the suspension control arms.
  19. Using Transverse Spring Compressor (J-33432-A), compress rear transverse spring. See Figure. Install the rear transverse spring to the vehicle. Install the rear transverse spring spacers, insulators and mounting brackets to the crossmember. Tighten the rear transverse spring mounting bracket bolts to specification.
  20. Position the transverse spring to the lower control arms and install the spring bolts, insulators and nuts. See Figure. Release and remove the Transverse Spring Compressor.
    21. NOTE: The rear transverse spring stud bolt must have a minimum of 2 threads showing above the nut.
  21. Set the transverse spring stud height to the height measured during removal. See Figure. Install the retainers to the bolts.
  22. Carefully position the wiring harness into the L-shaped brackets along the driveline support assembly. See Figure. Align the harness retainer locator to the hole in the forward bracket, and secure in place.
  23. Install the transmission shift cable and bracket into position. Connect the transmission shift cable to the transmission shift lever. Press to secure the cable. Install the nuts retaining the transmission shift cable bracket to the transmission. Tighten the transmission shift cable bracket retaining nuts to specification. See TORQUE SPECIFICATIONS .
    24. CAUTION: During this step, the propeller shaft hub clamp bolt is tightened finger-tight only. Vehicle must be completely assembled, ran to operating temperature and allowed to cool to room temperature before final-tightening the propeller shaft hub clamp bolt.
  24. Hand-tighten the propeller shaft hub clamp bolt, until finger-tight only. See Figure. Remove the propeller input shaft front bearing positioning bolts (M10 - 1.5 X 55 mm) installed into driveline support assembly upon removal. Install the 2 driveline support assembly plastic plugs and tighten to specification. See Figure. See TORQUE SPECIFICATIONS .
  25. Install the driveline tunnel closeout panel bolts and driveline tunnel closeout panel. See Figure. Tighten the driveline tunnel closeout panel bolts to specification. Remove the tie-off retainer from the left muffler assembly.
  26. Slide the muffler blade into the exhaust hanger. Install a NEW muffler gasket. Install exhaust muffler bolts and tighten to specification. Position the stabilizer shaft upwards. Install the rear stabilizer shaft brackets and insulators. Install the rear stabilizer shaft bracket bolts and nuts and tighten to specification. See Figure.
  27. Install the catalytic converter assembly. See CATALYTIC CONVERTERS .
  28. Install the rear tire and wheel assemblies. Tighten wheel lug nuts to specification. Connect the negative battery cable.
  29. Program the Remote Keyless Entry (RKE) transmitters. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT.
    30. CAUTION: The following steps must be performed in order to provide proper alignment of the propeller shaft hub, the propeller input shaft and the propeller input shaft front bearing.
  30. Start and idle engine until normal operating temperature is reached.
  31. Turn engine off and allow powertrain to cool to room temperature.
  32. Raise and support vehicle.
  33. Tighten propeller shaft hub clamp bolt to specification. See TORQUE SPECIFICATIONS . See Figure.
  34. Install engine flywheel housing access plug.
  35. Lower the vehicle.
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