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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 999 (Automatic Transmission - ALLISON (Introduction, Service & Replacement)) >> Repair Instructions >> Transmission Replacement (With 6.6L Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install J 21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
    Fig 1: Installing J 21366 To The Converter Housing (With 6.6L Engine)
    GM702530Courtesy of GENERAL MOTORS CORP.
  2. Raise the transmission into place while simultaneously installing the transmission fill tube.
  3. Remove the J 21366.
  4. Align the transmission with the engine using the alignment dowels located at the rear of the engine.
    NOTE: Refer to Fastener Notice .
    IMPORTANT: Do not install the transmission by drawing it to the engine using the studs and bolts.
    5. IMPORTANT: Ensure that the torque converter can be rotated before tightening the bolts and studs.
    Fig 2: Converter Housing Bolts And Studs (With 6.6L Engine)
    GM686685Courtesy of GENERAL MOTORS CORP.
  5. Install the converter housing bolts and studs.

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

    6. Fig 3: Installing Wire Harness/Vent Tube Bracket And Nut To The Converter Housing Stud (With 6.6L Engine)
    GM702529Courtesy of GENERAL MOTORS CORP.
  6. Install the wire harness/vent tube bracket and nut to the converter housing stud.

    Tighten:  Tighten the nut to 18 N.m (13 lb ft).

    7. Fig 4: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  7. Install the transmission fill tube and nuts to the converter housing studs.

    Tighten:  Tighten the nuts to 18 N.m (13 lb ft).

  8. If the vehicle is equipped with a PTO unit, connect and/or install the components at this time.
    9. Fig 5: Removing The Safety Chain From Around The Transmission (With 6.6L Engine)
    GM702527Courtesy of GENERAL MOTORS CORP.
  9. Remove the safety chain from around the transmission.
  10. Install the transfer case, if the vehicle is equipped with 4WD.
    11. Fig 6: Locating Transmission Mount Bolts
    GM702771Courtesy of GENERAL MOTORS CORP.
  11. If the vehicle is a 2WD, install the transmission mount.
  12. If the vehicle is a 2WD, install the transmission mount bolts (1).

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

    13. Fig 7: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  13. Install the transmission support.
  14. If the vehicle is a 2WD, install the transmission support bolts and nuts.
  15. If the vehicle is a 2WD, install the transmission support bracket bolts.

    Tighten:  Tighten the bolts/nuts to 95 N.m (70 lb ft).

    16. Fig 8: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  16. If the vehicle is a 2WD, install the transmission mount nuts.

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

  17. Remove the transmission jack.
  18. If the vehicle is a 2WD, install the propeller shaft. Refer to Propeller Shaft Replacement - One Piece orPropeller Shaft Replacement - Two Piece in Propeller Shaft.
  19. Position the exhaust hanger and install the bolts.

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

  20. Position the wiring harness branches.
  21. Connect the PNP switch electrical connectors.
    Fig 9: Exhaust Hanger Bolts (With 6.6L Engine)
    GM694239Courtesy of GENERAL MOTORS CORP.
    22. Fig 10: Connecting The Transmission Main Electrical Connector (With 6.6L Engine)
    GM702524Courtesy of GENERAL MOTORS CORP.
  22. Connect the transmission main electrical connector (2).
    23. Fig 11: Connecting The Output Speed Sensor Electrical Connector (With 6.6L Engine)
    GM702774Courtesy of GENERAL MOTORS CORP.
  23. Connect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and has been connected during the transfer case installation.
  24. Connect the turbine speed sensor (1) and the input speed sensor (2) electrical connectors.
    25. Fig 12: Installing The Fuel Line Bracket And Nut To The Transmission Converter Housing Stud (With 6.6L Engine)
    GM702523Courtesy of GENERAL MOTORS CORP.
  25. Install the fuel line bracket and nut to the transmission converter housing stud.

    Tighten:  Tighten the nut to 18 N.m (13 lb ft).

    26. Fig 13: Installing The Fuel Line Retainer And Bolts To The Left Side Of The Transmission (With 6.6L Engine)
    GM702521Courtesy of GENERAL MOTORS CORP.
  26. Install the fuel line retainer (1) and bolts to the left side of the transmission.

    Tighten:  Tighten the bolts to 2.5 N.m (22 lb in).

    27. Fig 14: Installing The Shift Cable Bracket And Bolts To The Transmission (With 6.6L Engine)
    GM686689Courtesy of GENERAL MOTORS CORP.
  27. Install the shift cable bracket (2) and bolts to the transmission.

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

    28. Fig 15: Installing Shift Cable To The Bracket And The Selector Lever Ball Stud (With 6.6L Engine)
    GM686691Courtesy of GENERAL MOTORS CORP.
  28. Install the shift cable to the bracket (3) and the selector lever ball stud (5).
    29. Fig 16: Removing Access Hole Cover On The Converter Housing (With 6.6L Engine)
    GM713136Courtesy of GENERAL MOTORS CORP.
  29. Remove the access hole cover (1) on the converter housing in order to rotate the converter and align the first torque converter bolt.
    30. Fig 17: Torque Converter Bolts (With 6.6L Engine)
    GM702519Courtesy of GENERAL MOTORS CORP.
  30. If reusing the torque converter bolts, clean the bolt threads and apply Loctite 242 GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads prior to installation.
  31. Install the torque converter bolts.

    Tighten:  Tighten the bolts to 60 N.m (44 lb ft).

  32. Install the converter housing access hole cover.
    33. Fig 18: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  33. Install the engine protection shield and bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    34. Fig 19: Installing The Starter Motor Bolts (With 6.6L Engine)
    GM660305Courtesy of GENERAL MOTORS CORP.
  34. Position and install the starter motor bolts.

    Tighten:  Tighten the bolts to 78 N.m (58 lb ft).

    35. Fig 20: Installing Solenoid Wire And Nut To The Starter (With 6.6L Engine)
    GM674619Courtesy of GENERAL MOTORS CORP.
  35. Install the solenoid wire and nut to the starter.

    Tighten:  Tighten the nut to 3.4 N.m (30 lb in).

  36. Install the positive battery cable and nut to the starter.

    Tighten:  Tighten the nut to 9 N.m (80 lb in).

    37. Fig 21: View Of Wheelhouse Panel & Push-In Retainers
    GM401885Courtesy of GENERAL MOTORS CORP.
  37. Install the inner panel (1).
  38. Connect any harness retainers to the inner panel.
  39. Install the right front wheel house inner panel retainers (2).
  40. Install the right front wheel and tire.
    41. Fig 22: Installing Transmission Oil Cooler Line (With 6.6L Engine)
    GM686709Courtesy of GENERAL MOTORS CORP.
  41. Remove the plugs from the transmission oil cooler line fittings in the transmission case, if necessary.
  42. Flush the transmission oil cooler and lines, if necessary. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test .
  43. Connect the transmission oil cooler lines (1, 2) to the transmission.
  44. Lower the vehicle.
  45. Connect both negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) .
  46. Fill the transmission with new transmission fluid.
  47. Install the transmission fluid level indicator.
  48. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. Refer to FastLearn Procedure .
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