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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) >> 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. Disconnect the energy storage box (ESB). Refer to Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2) in Engine Electrical.
  2. Disconnect 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.
  3. Remove the intake manifold. Refer to Intake Manifold Replacement .
  4. Remove the 3-phase cable bracket cover bolt (1).
    Fig 1: Removing The 3-Phase Cable Bracket Cover Bolt
    GM1237060Courtesy of GENERAL MOTORS CORP.
    5. Fig 2: Removing Starter/Generator Control Module (SGCM) Cover Bolts And Cover
    GM1237061Courtesy of GENERAL MOTORS CORP.
  5. Remove the starter/generator control module (SGCM) cover bolts and cover.
  6. Remove the 3-phase cable nuts.
  7. Remove the 3-phase cable from the SGCM studs.
    8. Fig 3: Removing The Transmission Fill Tube Bolt
    GM1284303Courtesy of GENERAL MOTORS CORP.
  8. From under the hood, remove the transmission fill tube bolt. Reposition the fill tube.
  9. Drain the cooling system and engine block. Refer to Draining and Filling Cooling System (with HP2) in Engine Cooling.
  10. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  11. Drain the transmission fluid.
  12. Remove 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 4: View Of Transfer Case & Transmission
    GM828574Courtesy of GENERAL MOTORS CORP.
  13. Remove the rear propeller shaft, if vehicle is a 2-wheel drive (2WD). Refer to Propeller Shaft Replacement - One Piece in Propeller Shaft.
  14. If vehicle is a 2WD, support the engine with a suitable adjustable jack.
    IMPORTANT: If the vehicle is a 2WD, it is necessary to remove the crossbar, in order to remove the transmission.
  15. If vehicle is a 2WD, remove the crossbar bolts and bar.
    Fig 5: View Of Crossbar Bolts & Bar (2WD)
    GM328107Courtesy of GENERAL MOTORS CORP.
  16. Support the transmission with a transmission jack.
  17. Remove the transmission mount nuts.
    Fig 6: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  18. Remove the transmission support bolts and nuts.
  19. Raise the transmission slightly and remove the transmission support.
    Fig 7: View Of Transmission Crossmember
    GM702036Courtesy of GENERAL MOTORS CORP.
  20. Remove the catalytic converter. Refer to Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines) in Engine Exhaust.
  21. Lower the transmission slightly, in order to gain access to the top of the transmission.
    22. Fig 8: View Of Transmission Heat Shield Bolts & Shield
    GM394459Courtesy of GENERAL MOTORS CORP.
  22. Remove the transmission heat shield bolts and shield.
  23. Remove the connector position assurance (CPA) retainer.
  24. Disconnect the park/neutral position (PNP) switch electrical connector (2).
    Fig 9: Disconnecting The Park/Neutral Position (PNP) Switch Electrical Connector
    GM1284299Courtesy of GENERAL MOTORS CORP.
    25. Fig 10: View Of Transmission Harness 20-Way Connector & VSS Electrical Connector
    GM858994Courtesy of GENERAL MOTORS CORP.
  25. Disconnect the transmission harness 20-way connector (1) from the internal harness pass-through connector.

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

  26. If vehicle is a 2WD, disconnect the vehicle speed sensor (VSS) (2).
    27. Fig 11: View Of Bolt Securing Fuel Line Bracket To Left Side Of Transmission
    GM396800Courtesy of GENERAL MOTORS CORP.
  27. Remove the bolt that secures the fuel line bracket to the left side of the transmission.
  28. Reposition the harness out of the way.
    29. Fig 12: View Of Range Selector Cable End At Transmission Range Selector Lever Ball Stud
    GM738167Courtesy of GENERAL MOTORS CORP.
  29. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1).
    30. Fig 13: View Of Selector Cable Bracket And Cable
    GM777649Courtesy of GENERAL MOTORS CORP.
  30. Remove the transmission range selector cable bracket bolts (1).
  31. Reposition the selector cable bracket (2) and cable out of the way.
    32. Fig 14: View Of Left Exhaust Heat Shield & Nuts
    GM707396Courtesy of GENERAL MOTORS CORP.
  32. Remove the driver side exhaust heat shield nuts (2).
  33. Remove the driver side exhaust heat shield (1).
    34. Fig 15: Removing The Driver Side Exhaust Heat Shield
    GM1195697Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the O-ring seal is removed with the hose.
  34. Remove the thermal bypass hose bolt.
  35. Reposition the thermal bypass hose clamp.
  36. Remove the thermal bypass hose from the fitting.
  37. Remove the coolant inlet pipe to stator bolt (4).
    Fig 16: Repositioning The Coolant Inlet Pipe
    GM1206694Courtesy of GENERAL MOTORS CORP.
  38. Reposition the inlet pipe (3) out of the way.
    39. Fig 17: Removing The Driver Side Closeout Cover Bolt And Cover
    GM1195702Courtesy of GENERAL MOTORS CORP.
  39. Remove the driver side closeout cover bolt and cover.
    40. Fig 18: Removing The Passenger Side Closeout Cover Bolt And Cover
    GM1195704Courtesy of GENERAL MOTORS CORP.
  40. Remove the passenger side closeout cover bolt and cover.
    41. Fig 19: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  41. Remove the engine shield bolts and shield, if necessary.
    42. IMPORTANT: It is highly recommended to use a 3/8 inch, 6 point shallow thin wall socket and a wobble extension to loosen the torque converter bolts and a 8 mm ball end hex key to remove the bolts in order to prevent possibly stripping the bolts.
    Fig 20: Removing The Torque Converter Bolts
    GM1195705Courtesy of GENERAL MOTORS CORP.
  42. Remove the torque converter bolts.
  43. Disconnect the transmission oil cooler lines from the transmission. Refer to Transmission Fluid Cooler Line Quick Connect Fitting .
    Fig 21: View Of Transmission Oil Cooler Lines
    GM396804Courtesy of GENERAL MOTORS CORP.
  44. Plug the transmission oil cooler lines and fittings.
  45. Lower the transmission, in order to access the 3-phase cable cover.
  46. Remove the 3-phase cable cover nuts (3).
  47. Remove the 3-phase cable nuts (4).
  48. Remove the 3-phase cable from the stator studs.
    Fig 22: Removing The 3-Phase Cable
    GM1237060Courtesy of GENERAL MOTORS CORP.
  49. Position the 3-phase cable up and out of the way, in order to access the fill tube bolt.
    50. Fig 23: View Of Fuel Pipe Bracket & Nut At Bellhousing
    GM1238747Courtesy of GENERAL MOTORS CORP.
  50. Remove the fuel line bracket nut and bracket from the upper left bellhousing stud.
  51. Remove the transmission vent hose bracket nut and bracket from the top bellhousing stud.
  52. Remove the vent hose from the transmission.
    53. Fig 24: Removing Transmission Studs And Bolts From The Engine
    GM1195707Courtesy of GENERAL MOTORS CORP.
  53. Remove the transmission studs (1) and bolts (2) to the engine.
    54. Fig 25: Removing The Transmission Nuts To The Engine
    GM1195708Courtesy of GENERAL MOTORS CORP.
  54. Remove the transmission nuts to the engine.
  55. Pull the transmission straight back in order to disengage the torque converter.
  56. Once the transmission is pulled back far enough, install J 21366 onto the bell housing in order to retain the torque converter.
  57. Once the transmission is far enough back, remove the driver side stator stud.
  58. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.
  59. Flush the transmission oil cooler and cooling lines if necessary. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096) or Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A) .
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