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Home >> Chevrolet >> 2011 >> Corvette ZR-1 >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Automatic Transmission - 6L80-E - Repair Instructions - On Vehicle) >> Repair Instructions - On Vehicle >> Transmission Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
Fig 1: Tilting Down Rear Of Driveline
GM321407Courtesy of GENERAL MOTORS CORP.
WARNING: Refer to Battery Disconnect Warning .
CAUTION: Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
CAUTION: When tilting down the rear of the driveline, observe the clearance between the rear of the engine and the composite dash panel. Do not allow the engine to rest unsupported against the composite dash panel, or vehicle damage may result.
CAUTION: When lowering and removing the rear of the driveline, observe the clearance between the rear of the transaxle assembly and the underbody to prevent damage.
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LS7 or LS9) or Battery Negative Cable Disconnection and Connection (LS3) .
  2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Remove the rear tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
  4. Remove the intermediate pipe assembly. Refer to Intermediate Pipe Replacement .
    5. Fig 2: View Of Tied Off Muffler Assembly
    GM1713450Courtesy of GENERAL MOTORS CORP.
  5. Tie off the LH muffler assembly to the underbody to support the muffler out of the way.
  6. Remove the RH muffler assembly. Refer to Exhaust Muffler Replacement - Right Side .
  7. Remove the floor panel tunnel reinforcement. Refer to Floor Panel Tunnel Panel Reinforcement Replacement .
    8. Fig 3: Rear Bellhousing Access Plug
    GM71469Courtesy of GENERAL MOTORS CORP.
  8. Using a flat-bladed screwdriver, remove the rear bellhousing access plug.
    9. NOTE: The following step must be performed to assure proper torque converter balance during installation.
  9. Matchmark the transmission flexplate to the transmission torque converter through the access hole in the rear bellhousing.
    10. Fig 4: Engine Flywheel & Flexplate
    GM71465Courtesy of GENERAL MOTORS CORP.
  10. Turn the engine flywheel through the starter motor opening until one of the flexplate to torque converter bolts lines up with the access hole.
    11. Fig 5: Flywheel Holding Tool
    GM1760254Courtesy of GENERAL MOTORS CORP.
  11. Install the J 42386-A  (1) to the engine flywheel, in order to keep the flywheel from turning.
    12. Fig 6: Flexplate & Torque Converter Bolt
    GM71434Courtesy of GENERAL MOTORS CORP.
  12. Remove the flexplate to torque converter bolt.
  13. Remove the J 42386-A  .
  14. Repeat steps 7-10 to remove the 2 remaining bolts.
    15. Fig 7: Plug Bolts
    GM1760256Courtesy of GENERAL MOTORS CORP.
  15. Remove the two plug bolts from the front of driveline support assembly.
    16. CAUTION: Refer to Fastener Caution .
    NOTE:
    • The propeller input shaft front bearing positioning bolts are intended to remain torqued to specification and in place UNTIL INSTRUCTED in the installation procedure.
    • Failure to use the minimum length fastener specified will prevent proper retention of the propeller input shaft front bearing during disassembly or installation.
  16. Install two bolts, M10 - 1.5 X 55 mm, or longer, in place of the plug bolts.

    The long bolts are located to maintain the propeller input shaft front bearing in original position during removal and installation.

    Tighten:  Tighten the propeller input shaft front bearing positioning bolts to 35 N.m (26 lb ft).

    17. Fig 8: View Of Engine Flywheel Housing Access Plug
    GM71455Courtesy of GENERAL MOTORS CORP.
  17. Using a flat-bladed screwdriver, remove the engine flywheel housing access plug.
    18. Fig 9: View Of Propeller Shaft Hub Clamp Bolt
    GM1760257Courtesy of GENERAL MOTORS CORP.
  18. Loosen the propeller shaft hub clamp bolt (1).

    Rotate the engine at the flywheel, if necessary for alignment.

    19. Fig 10: View Of Transmission Shift Cable Bracket & Retaining Nuts
    GM1673258Courtesy of GENERAL MOTORS CORP.
  19. Remove the nuts (3) retaining the transmission shift cable bracket (4) to the transmission.
  20. Disconnect the transmission shift control cable from the transmission shift lever.

    Unsnap to release the cable.

  21. Position the transmission shift cable (1) and bracket aside.
    22. Fig 11: Rear Shock Absorber Lower Mounting & Bolts
    GM180606Courtesy of GENERAL MOTORS CORP.
  22. Remove the rear transverse spring. Refer to Rear Transverse Spring Replacement .
  23. Support the lower control arm with a straight jack.
  24. Disconnect the outer tie rod end from the suspension knuckle. Refer to Tie Rod Replacement .
  25. Remove the shock absorber lower mounting bolt.
  26. Disconnect the lower ball joint from the suspension knuckle. Refer to Knuckle Replacement .
  27. Remove the straight jack from the control arm.
  28. Repeat steps 21-25 for the other side of the vehicle.
    29. Fig 12: Special Tool
    GM1714135Courtesy of GENERAL MOTORS CORP.
  29. Assemble the J 42055  .
  30. Install the J 42055  to a transmission jack.
  31. Position and firmly secure the J 42055  (1) with the transmission jack to the transmission.
  32. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  33. Remove the differential to transmission lower nut.
    34. Fig 13: Locating Transaxle Mounts & Nuts
    GM1710439Courtesy of GENERAL MOTORS CORP.
  34. Remove the transaxle mount to rear crossmember nuts (3).
    35. Fig 14: Transmission Jack Placement
    GM1714138Courtesy of GENERAL MOTORS CORP.
  35. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
  36. Using ONLY HAND TOOLS, remove the rear suspension crossmember retaining nuts.
    37. Fig 15: View Of Rear Suspension Crossmember
    GM180638Courtesy of GENERAL MOTORS CORP.
  37. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
    38. Fig 16: Locating Transaxle Mounts & Nuts
    GM1710439Courtesy of GENERAL MOTORS CORP.
  38. Remove the transaxle mount bracket to differential nuts (1).
  39. Remove the transaxle mount (2).
    40. Fig 17: View Of Wheel Drive Shaft
    GM1714139Courtesy of GENERAL MOTORS CORP.
  40. Using a pry bar, CAREFULLY release the axle shafts from the differential.
  41. Tie off the axle shafts to the underbody to support the shafts out of the way.

    The LH muffler assembly pipe toward the rear offers a good location to help support the LH axle shaft (1).

    42. Fig 18: View Of Wiring Harness Retainer
    GM1760260Courtesy of GENERAL MOTORS CORP.
  42. Release the retainer (1) securing (and positioning) the wiring harness to the L-shaped brackets along the driveline support assembly, then slide the harness up out of the brackets and position out of the way.
    43. Fig 19: Vehicle Speed Sensor (VSS) Electrical Connector
    GM180649Courtesy of GENERAL MOTORS CORP.
  43. SLOWLY lower the driveline approximately 5 cm (2 in), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.
  44. Disconnect the vehicle speed sensor (VSS) electrical connector.
    45. Fig 20: Wiring Harness Retainer
    GM71409Courtesy of GENERAL MOTORS CORP.
  45. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  46. Disconnect the wiring harness retainer clip from the top of the differential.
    47. Fig 21: View Of Transmission Harness 20-Way Connector
    GM1673257Courtesy of GENERAL MOTORS CORP.
  47. Disconnect the transmission harness 20-way connector (3).

    Depress both tabs on the connector and pull straight up; do not pry the connector.

  48. Remove the bolt retaining the transmission wiring harness to the LH side of the transmission case.
    49. Fig 22: View Of Wiring Harness & Top Of Transmission
    GM196198Courtesy of GENERAL MOTORS CORP.
  49. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt, and observe the relationship between the top rear of the differential and the lowest part of the rear compartment panel floor (the center storage compartment between the frame rails). The differential should not be lowered more than approximately EVEN with the specified body point of reference.

    The engine positive crankcase ventilation (PCV) pipes which route along the rear of the engine intake manifold will likely contact the dash panel.

  50. Release the wiring harness from the harness retainer along the top of the transmission.
  51. Check to be sure that the wiring harness is free from the driveline being removed.
    52. Fig 23: Upper & Lower Transmission Oil Cooler Lines
    GM1503871Courtesy of GENERAL MOTORS CORP.
  52. Disconnect the transmission oil cooler rear pipes from the junction fittings at the engine flywheel housing, then cap the pipes and plug the junction fittings to prevent contamination. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
    53. Fig 24: Removing/Installing Engine Flywheel Housing Bolts
    GM196199Courtesy of GENERAL MOTORS CORP.
  53. Using a block of wood to protect the engine oil pan, place a straight jack under the rear of the engine oil pan to support the engine from stressing the composite dash panel.
  54. Remove the five driveline support assembly to engine flywheel housing bolts.
    55. Fig 25: Bending Wiring Harness Bracket
    GM1760261Courtesy of GENERAL MOTORS CORP.
  55. Carefully bend the wiring harness bracket away from the driveline, toward the driveline tunnel wall in order to make a clear removal path for the driveline.
    56. Fig 26: Separating Driveline From Engine
    GM196200Courtesy of GENERAL MOTORS CORP.
    NOTE: The aid of an assistant will be necessary for the remaining steps.
  56. Have an assistant insert a flat bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the engine flywheel housing, then begin to pry the driveline loose from the engine.
    57. Fig 27: Driveline & Engine
    GM1760259Courtesy of GENERAL MOTORS CORP.
  57. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  58. SLOWLY lower the driveline, while simultaneously adjusting the angle of tilt and pulling the driveline away from the engine UNTIL the propeller input shaft at the front of the driveline support assembly just clears the engine flywheel housing.
  59. SLOWLY lower the driveline completely out of the vehicle.
    60. Fig 28: Raising Driveline
    GM196196Courtesy of GENERAL MOTORS CORP.
  60. Position the chainfall, or equivalent, of a lift device in a way which will protect the transmission oil cooler rear pipes and the rear exhaust hangers located on the driveline support assembly.
  61. Using the lift device, raise the driveline to relieve the weight from the transmission jack.
  62. Disconnect the J 42055  from the transmission jack ONLY, the J 42055  will provide stability to the driveline components while working on a bench.
  63. Position the driveline on a workbench with the lift device still attached.
  64. Support the driveline support assembly and the differential for additional balance.
  65. Remove the lift device from the driveline.
    66. Fig 29: View Of Transmission Oil Cooler Pipes
    GM1760308Courtesy of GENERAL MOTORS CORP.
  66. Disconnect the transmission oil cooler rear pipes from the fittings on the transmission, then cap the pipes and plug the transmission fittings to prevent contamination. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
    67. Fig 30: View Of Transmission, Driveline Support Assembly & Bolts
    GM71442Courtesy of GENERAL MOTORS CORP.
  67. Remove the transmission to driveline support assembly bolts/studs.
  68. Insert a flat-bladed screwdriver, or similar tool, between the edge of the driveline support assembly and the transmission, then begin to pry the driveline support assembly loose from the transmission.
  69. Slowly slide the driveline support assembly away from the transmission while supporting the transmission torque converter.
  70. Using a strap positioned from side to side, secure the transmission torque converter to the transmission.
    71. Fig 31: Differential, Transmission Bolts & Nuts
    GM71505Courtesy of GENERAL MOTORS CORP.
  71. Remove the differential to transmission bolts and nuts.
    72. NOTE: Use care when separating the differential from the transmission to not damage the transmission output shaft seal in the differential plate.
  72. SLOWLY slide the differential from the transmission.
    73. Fig 32: Differential & Plate
    GM71504Courtesy of GENERAL MOTORS CORP.
  73. Remove the differential plate from the differential.
  74. Remove the transmission from the J 42055  , if necessary.
  75. Flush the transmission cooler lines. Refer to Transmission Fluid Cooler Flushing and Flow Test .
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