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Home >> Chevrolet >> 2005 >> Chevy Express H1500, Van Passenger >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Automatic Transmission - 4L80-E/4L85-E - Introduction & Repair Instructions) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

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  1. Support the transmission with a transmission jack.
  2. Raise the transmission into place.
  3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter.
    4. IMPORTANT:
    • The torque converter must rotate freely by hand.
    • Do not install the transmission fluid fill tube.
    Fig 1: Transmission-To-Engine Bolts
    GM609232Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the bolts that secure the transmission to the engine.

    Tighten:  Tighten the studs and the bolts to 47 N.m (34 lb ft).

    5. Fig 2: Torque Converter, Engine Flywheel & Bolts
    GM609227Courtesy of GENERAL MOTORS CORP.
  5. Install the bolts securing the torque converter to the engine flywheel.

    Tighten: 

    1. First tighten all the bolts finger tight in order to insure proper converter seating.
    2. Tighten the bolts to 63 N.m (46 lb ft).

  6. If equipped with All Wheel Drive (AWD), install the transfer case. Refer to Transfer Case Assembly Replacement in Driveline/Axle.
    7. Fig 3: Vehicle Harness Wires, Harness Clips, Tubes, Brackets & Lines That May Interfere With Transmission Removal
    GM609237Courtesy of GENERAL MOTORS CORP.
  7. Install the wiring harness connectors to the vehicle speed sensor and the park neutral position switch.
  8. Position and install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal.
  9. Remove the two plugs from the transmission case cooling line connectors.
  10. Install the transmission oil cooler pipes. Refer to Transmission Fluid Cooler Hose/Pipe Replacement .
  11. Install the transmission fluid fill tube and the fill tube seal. Refer to Filler Tube and Seal Replacement 
  12. Install the transmission vent hose and the wiring harness to the transmission.
    13. Fig 4: Automatic Transmission Range Selector Cable
    GM105219Courtesy of GENERAL MOTORS CORP.
  13. Install the starter motor. Refer to Starter Motor Replacement (4.8L, 5.3L, and 6.0L) or Starter Motor Replacement (4.3L) in Engine Electrical.
  14. Install the exhaust pipe to the exhaust manifolds and the muffler assembly to the exhaust pipe. Refer to Catalytic Converter Replacement (4.3L) or Catalytic Converter Replacement (Dual Exhaust - Right) or Catalytic Converter Replacement (Dual Exhaust - Left) in Engine Exhaust.

    Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.

  15. Remove the transmission jack and the engine support stands.
  16. Install the rear propeller shaft.
  17. Install the transmission range select cable to the transmission range select lever and the bracket.
  18. Flush the transmission oil cooler and the pipes whenever you remove the transmission for overhaul, or replacement of the torque converter, the pump, or the transmission case. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A) or Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096) .
  19. Remove the safety stands.
  20. Lower the vehicle.
  21. Fill the transmission to the proper level with approved fluid.
  22. Connect the battery negative cable assembly to the battery negative terminal.

    Tighten:  Tighten the terminal bolt to 15 N.m (11 lb ft).

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