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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 965 (Manual Transmission -- ZF S6-650) >> Repair Instructions >> Transmission Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet 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 in General Information.
    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.
  5. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece orPropeller Shaft Replacement - Two Piece in Propeller Shaft.
  6. If equipped with 4 wheel drive (4WD), remove the transfer case. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG263-NP1 (Selectable) or Transfer Case Assembly Replacement in 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.
    Fig 1: Disconnecting The Clutch Actuator Cylinder Line Retaining Clips
    GM689678Courtesy of GENERAL MOTORS CORP.
  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)
    Fig 2: Disconnecting The Electrical Connectors (6.6L Engine)
    GM776052Courtesy of GENERAL MOTORS CORP.
  10. Remove the engine harness clips (1) from the fuel feed/return brackets.
  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.
  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)
    Fig 3: Disconnecting The Electrical Connectors (8.1L Engine)
    GM776054Courtesy of GENERAL MOTORS CORP.
  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.
    20. Fig 4: Removing The Vent Hose Clip From The Bracket (4WD)
    GM775346Courtesy 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.
    22. Fig 5: Removing The Vent Hose Clip From The Fuel Feed/Return Bracket (4WD)
    GM776223Courtesy 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 Replacement (4.3L Engine) or Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines) or Starter Motor Replacement (6.6L (LB7) Engine) or Starter Motor Replacement (6.6L (LLY) Engine) or Starter Motor Replacement (8.1L Engine) in Engine Electrical.
    24. Fig 6: Removing The Exhaust Pipe Hanger Bracket Bolts And Bracket
    GM694241Courtesy 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. Refer to Transmission Support Replacement in Frame and Underbody.
    27. Fig 7: Removing The Transmission Bolts/Studs (6.6L Engine)
    GM776274Courtesy 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.
    31. Fig 8: Removing The Transmission Studs
    GM776275Courtesy 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.
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