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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1008 (Automatic Transmission - 4L60-E/4L65-E (Introduction, Service & Replacement)) >> Repair Instructions >> Transmission Replacement (5.3L Engine w/RPO HP2) >> Installation Procedure

Installation 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. Install the transmission to the vehicle while simultaneously installing the fluid level indicator tube.
    Fig 1: Installing The Transmission To The Vehicle
    GM1195708Courtesy of GENERAL MOTORS CORP.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Once the transmission is half way installed, install the driver side stator stud.

    Tighten:  Tighten the stud to 16 N.m (12 lb ft).

  3. Once the transmission is half way installed, remove J 21366 from the bellhousing.
  4. Slide the transmission forward in order to engage the torque converter.
  5. Install the transmission nuts to the engine.

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

  6. Install the transmission studs (1) and bolts (2) to the engine.

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

    Fig 2: Installing The Transmission Studs And Bolts To The Engine
    GM1195707Courtesy of GENERAL MOTORS CORP.
    7. Fig 3: View Of Fuel Pipe Bracket & Nut At Bellhousing
    GM1238747Courtesy of GENERAL MOTORS CORP.
  7. Install the vent hose to the transmission.
  8. Install the transmission vent hose bracket and nut to the top bellhousing stud.

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

  9. Install the fuel line bracket and nut to the upper left bellhousing stud.

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

    10. Fig 4: Installing The 3-Phase Cable
    GM1237060Courtesy of GENERAL MOTORS CORP.
  10. Position the 3-phase cable to the stator studs.
  11. Install the 3-phase cable nuts (4).

    Tighten: 

    1. Tighten the nuts a first pass to 14 N.m (10 lb ft).
    2. Tighten the nuts a final pass to 14 N.m (10 lb ft).

    12. IMPORTANT: The 3-phase cable cover studs may have a tendency to spread apart when the nuts are torqued. Once they have spread apart, they may not align with the holes in the cover. The studs can be realigned by squeezing them together at the tips. Each stud has a hex on the tip end where a tool cane be place without damaging the threads.
  12. Install the 3-phase cable cover and nuts (3).

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

  13. Raise the transmission to a level position.
    14. Fig 5: Removing The Torque Converter Access Plug
    GM408374Courtesy of GENERAL MOTORS CORP.
  14. Remove the torque converter access plug.
  15. Rotate the torque converter in order to align the converter bolt holes with the flexplate holes.
    16. IMPORTANT: It is highly recommended to use a 8 mm ball end hex key to install and hand tighten the torque converter bolts, then a 3/8 inch, 6 point shallow thin wall socket and a wobble extension to torque the torque converter bolts in order to prevent possibly stripping the bolts.
    Fig 6: Installing The Torque Converter Bolts
    GM1195705Courtesy of GENERAL MOTORS CORP.
  16. Install the torque converter bolts.

    Tighten:  Tighten the bolts to 63 N.m (46 lb ft).

    17. Fig 7: Installing The Torque Converter Access Plug
    GM408374Courtesy of GENERAL MOTORS CORP.
  17. Install the torque converter access plug.
  18. Install the engine shield and bolts, if necessary.
    Fig 8: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.

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

    19. Fig 9: Installing The Passenger Side Closeout Cover And Bolt
    GM1195704Courtesy of GENERAL MOTORS CORP.
  19. Install the passenger side closeout cover and bolt.

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

  20. Install the driver side closeout cover and bolt.
    Fig 10: Installing The Driver Side Closeout Cover And Bolt
    GM1195702Courtesy of GENERAL MOTORS CORP.

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

    21. Fig 11: Positioning The Inlet Pipe To The Stator
    GM1206694Courtesy of GENERAL MOTORS CORP.
  21. Position the inlet pipe (3) to the stator.
  22. Install the coolant inlet pipe to stator bolt (4).

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

    23. Fig 12: Installing The Thermal Bypass Hose To The Fitting
    GM1195697Courtesy of GENERAL MOTORS CORP.
  23. Install the thermal bypass hose to the fitting.
  24. Position the thermal bypass hose clamp.
    IMPORTANT: Ensure that there is a O-ring seal on the bypass hose end that attaches to the transmission.
  25. Install the thermal bypass hose bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

    26. Fig 13: View Of Left Exhaust Heat Shield & Nuts
    GM707396Courtesy of GENERAL MOTORS CORP.
  26. Install the driver side exhaust heat shield (1).
  27. Install the driver side exhaust heat shield nuts (2).

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

    28. Fig 14: View Of Selector Cable Bracket And Cable
    GM777649Courtesy of GENERAL MOTORS CORP.
  28. Position the selector cable bracket (2) and cable.
  29. Install the transmission range selector cable bracket bolts (1).

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

    30. Fig 15: View Of Range Selector Cable End At Transmission Range Selector Lever Ball Stud
    GM738167Courtesy of GENERAL MOTORS CORP.
  30. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1).
    31. Fig 16: View Of Bolt Securing Fuel Line Bracket To Left Side Of Transmission
    GM396800Courtesy of GENERAL MOTORS CORP.
  31. Position the harness to the transmission.
  32. Install the bolt that secures the fuel line bracket to the left side of the transmission.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  33. If vehicle is a 2WD, connect the VSS (2).
  34. Connect the transmission harness 20-way connector (1) to the internal harness pass-through connector.
    Fig 17: View Of Transmission Harness 20-Way Connector & VSS Electrical Connector
    GM858994Courtesy of GENERAL MOTORS CORP.
    35. Fig 18: Connecting The PNP Switch Electrical Connector
    GM1284299Courtesy of GENERAL MOTORS CORP.
  35. Connect the PNP switch electrical connector (2).
  36. Install the CPA retainer.
    37. Fig 19: View Of Transmission Heat Shield Bolts & Shield
    GM394459Courtesy of GENERAL MOTORS CORP.
  37. Install the transmission heat shield and bolts.

    Tighten:  Tighten the bolts to 17 N.m (13 lb ft).

  38. Raise the transmission slightly.
  39. Install the catalytic converter. Refer to Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) in Engine Exhaust.
  40. Install the transmission support.
    Fig 20: View Of Transmission Crossmember
    GM702036Courtesy of GENERAL MOTORS CORP.
  41. Install the transmission support bolts and nuts.

    Tighten:  Tighten the bolts to 70 N.m (50 lb ft).

  42. Lower the transmission onto the support.
    43. Fig 21: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  43. Install the transmission mount nuts.

    Tighten:  Tighten the nuts to 40 N.m (29 lb ft).

  44. Remove the support from the transmission.
    45. Fig 22: View Of Crossbar Bolts & Bar (2WD)
    GM328107Courtesy of GENERAL MOTORS CORP.
  45. If vehicle is a 2WD, remove the support from the engine.
  46. If vehicle is a 2WD, install the crossbar bolts and bar.

    Tighten:  Tighten the bolts to 100 N.m (74 lb ft).

  47. If vehicle is a 2WD, install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece in Propeller Shaft.
    48. Fig 23: View Of Transmission Oil Cooler Lines
    GM396804Courtesy of GENERAL MOTORS CORP.
  48. Remove the plugs from the transmission oil cooler lines and fittings.
  49. Connect the transmission oil cooler lines to the transmission. Refer to Transmission Fluid Cooler Line Quick Connect Fitting .
  50. Install the transfer case, if equipped. Refer to Transfer Case Assembly Replacement in Transfer Case - NVG 261-NP2, or Transfer Case Assembly Replacement in Transfer Case - NVG 246-NP8.
    Fig 24: View Of Transfer Case & Transmission
    GM828574Courtesy of GENERAL MOTORS CORP.
    51. Fig 25: Positioning The Fill Tube
    GM1284303Courtesy of GENERAL MOTORS CORP.
  51. From under the hood, position the fill tube. Install the fill tube bolt.

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

    52. Fig 26: Installing The 3-Phase Cable To The SGCM Studs
    GM1237061Courtesy of GENERAL MOTORS CORP.
  52. Install the 3-phase cable to the SGCM studs.
  53. Install the 3-phase cable nuts.

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

  54. Install the SGCM cover and bolts.

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

    55. Fig 27: Installing The 3-Phase Cable Bracket Cover
    GM1237060Courtesy of GENERAL MOTORS CORP.
  55. Install the 3-phase cable bracket cover bolt (1).

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

  56. Install the intake manifold. Refer to Intake Manifold Replacement .
  57. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  58. Refill the cooling system and engine block. Refer to Draining and Filling Cooling System (with HP2) in Engine Cooling.
  59. Connect the ESB. Refer to Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2) in Engine Electrical.
  60. Fill the transmission to the correct capacity using DEXRON® III transmission fluid. Refer to Capacities - Approximate Fluid in Maintenance and Lubrication.
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