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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1160 (Drive Shaft) >> Repair Instructions >> Driveline Support Assembly Replacement (Automatic Transmission) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Failure to follow the proper removal and installation procedures may result in damage to the engine crankshaft thrust bearing.
NOTE: 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.
NOTE: 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.
Fig 1: Clearance Between Rear Of Engine & Composite Dash Panel
G01419612Courtesy of GENERAL MOTORS CORP.

Caution: Refer to BATTERY DISCONNECT CAUTION .

  1. Disconnect the negative battery cable.
  2. Raise and 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 in Tires and Wheels.
  4. Remove the catalytic converters. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  5. Tie off the LH muffler assembly to the underbody to support the muffler out of the way.
    Fig 2: Tying LH Muffler Assembly To Underbody
    G01419613Courtesy of GENERAL MOTORS CORP.
  6. Remove the RH muffler assembly. Refer to MUFFLER REPLACEMENT - RIGHT in Engine Exhaust.
  7. Remove the driveline tunnel closeout panel. Refer to DRIVELINE TUNNEL CLOSEOUT PANEL REPLACEMENT  .
  8. Using a flat bladed screwdriver, remove the rear bellhousing access plug.
    Fig 3: Removing Rear Bellhousing Access Plug
    G01419614Courtesy of GENERAL MOTORS CORP.

    Important:  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. Remove the transmission flexplate to transmission torque converter bolts. Refer to FLEXPLATE TO TORQUE CONVERTER BOLTS in Automatic Transmission - 4L60-E.
  11. Remove the 2 plastic plugs from the front of driveline support assembly.
    Fig 4: Removing Plastic Plugs From Front Of Driveline Support Assembly
    G01419615Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE .

    Important: 

    • The propeller input shaft front bearing positioning bolts are intended to remain torqued to specification and in place UNTIL INSTRUCTED in the installation procedure.
    • The bolts are to be removed, and the plastic plugs reinstalled after the installation is complete.
    • Failure to use the minimum length fastener specified will prevent proper retention of the propeller input shaft front bearing during disassembly or installation.
  12. Install 2 bolts, M10 - 1.5 X 55 mm, or longer, in place of the plastic plugs.

    (The long bolts are used 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).

  13. Using a flat bladed screwdriver, remove the engine flywheel housing access plug.
    Fig 5: Removing Engine Flywheel Housing Access Plug
    G01419616Courtesy of GENERAL MOTORS CORP.
  14. Loosen the propeller shaft hub clamp bolt (1). Rotate the engine at the flywheel, if necessary for alignment.
    Fig 6: Loosening Propeller Shaft Hub Clamp Bolt
    G01419617Courtesy of GENERAL MOTORS CORP.
  15. Remove the nuts retaining the transmission shift cable bracket to the transmission.
    Fig 7: Removing Transmission Shift Cable Bracket Retaining Nuts
    G01419618Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the transmission shift control cable from the transmission shift lever.
    Fig 8: Disconnecting Transmission Shift Control Cable From Transmission Shift Lever
    G01419619Courtesy of GENERAL MOTORS CORP.

    Unsnap to release the cable.

  17. Reposition the transmission shift cable and bracket.
  18. Remove the rear transverse spring. Refer to REAR TRANSVERSE SPRING REPLACEMENT .
  19. Support the lower control arm with a straight jack.
  20. Disconnect the outer tie rod end from the suspension knuckle. Refer to TIE ROD REPLACEMENT (OUTER END) or TIE ROD REPLACEMENT (SUSPENSION LINK) .
  21. Remove the shock absorber lower mounting bolt.
    Fig 9: Removing Shock Absorber Lower Mounting Bolt
    G01419620Courtesy of GENERAL MOTORS CORP.
  22. Disconnect the lower ball joint from the suspension knuckle. Refer to KNUCKLE REPLACEMENT .
  23. Remove the straight jack from the control arm.
  24. Repeat steps 19 through 23 for the other side of the vehicle.
  25. Assemble the J 42055. 
  26. Install the J 42055  to a transmission jack.
  27. Position and firmly secure the J 42055  with the transmission jack to the transmission.
    Fig 10: Positioning J 42055
    G01419621Courtesy of GENERAL MOTORS CORP.
  28. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  29. Remove the transaxle mount to rear crossmember nuts.
    Fig 11: Removing Rear Crossmember Transaxle Mount Nuts
    G01419622Courtesy of GENERAL MOTORS CORP.
  30. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
    Fig 12: Positioning Transmission Jack
    G01419623Courtesy of GENERAL MOTORS CORP.
  31. Using ONLY HAND TOOLS, remove the rear suspension crossmember retaining nuts.
  32. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
    Fig 13: Removing Crossmember
    G01419624Courtesy of GENERAL MOTORS CORP.
  33. Remove the transaxle mount bracket to differential bolts.
    Fig 14: Removing Transaxle Mount Bracket
    G01419625Courtesy of GENERAL MOTORS CORP.
  34. Remove the transaxle mount with bracket.

    Removing the transaxle mount will allow for greater stability on a workbench after the driveline is removed.

  35. Using a pry bar, CAREFULLY release the wheel drive shafts from the differential.
  36. Tie off the wheel drive 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 wheel drive shaft (1).

    Fig 15: Tying Off Wheel Drive Shafts To Underbody
    G01419626Courtesy of GENERAL MOTORS CORP.
  37. 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.
    Fig 16: Releasing Retainer And Removing Wiring Harness
    G01419627Courtesy of GENERAL MOTORS CORP.
  38. SLOWLY lower the driveline approximately 51 mm (2.0 in), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.
  39. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 17: Disconnecting Vehicle Speed Sensor (VSS) Electrical Connector
    G01419628Courtesy of GENERAL MOTORS CORP.
  40. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  41. Disconnect the wiring harness retainer clip from the top of the differential.
    Fig 18: Disconnecting Wiring Harness Retainer Clip From Top Of Differential
    G01419629Courtesy of GENERAL MOTORS CORP.
  42. Disconnect the transmission harness 20-way connector.

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

    Fig 19: Disconnecting Transmission Harness 20-Way Connector
    G01419630Courtesy of GENERAL MOTORS CORP.
  43. Disconnect the park/neutral position switch electrical connectors.
    Fig 20: Disconnecting Park/Neutral Position Switch Electrical Connectors
    G01419631Courtesy of GENERAL MOTORS CORP.
  44. Remove the bolt retaining the transmission wiring harness to the LH side of the transmission case.
  45. 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.
    Fig 21: Lowering Driveline
    G01419632Courtesy of GENERAL MOTORS CORP.

    (The engine positive crankcase ventilation (PCV) pipes which route along the rear of the engine intake manifold [LS1 only] will likely contact the dash panel.)

  46. Release the wiring harness from the harness retainer along the top of the transmission.
  47. Check to be sure that the wiring harness is free from the driveline being removed.
  48. 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.
    Fig 22: Disconnecting Transmission Oil Cooler Rear Pipes
    G01419633Courtesy of GENERAL MOTORS CORP.
  49. Using a block of wood to protect the engine oil pan, place a jack under the rear of the engine oil pan to support the engine, and prevent contact with the composite dash panel.
  50. Remove the five driveline support assembly to engine flywheel housing bolts.
    Fig 23: Removing Driveline Support Assembly To Engine Flywheel Housing Bolts
    G01419634Courtesy of GENERAL MOTORS CORP.
  51. Carefully bend the wiring harness bracket away from the driveline and toward the driveline tunnel wall in order to make a clear removal path for the driveline.
    Fig 24: Bending Wiring Harness Bracket Away From Driveline
    G01419635Courtesy of GENERAL MOTORS CORP.

    Important:  The aid of an assistant will be necessary for the remaining steps.

  52. 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.
    Fig 25: Prying Driveline Loose
    G01419636Courtesy of GENERAL MOTORS CORP.
  53. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  54. 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.
    Fig 26: Pulling Driveline Away From Engine
    G01419637Courtesy of GENERAL MOTORS CORP.
  55. SLOWLY lower the driveline completely out of the vehicle.
  56. 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.
  57. Using the lift device, raise the driveline to relieve the weight from the transmission jack.
  58. Disconnect the J 42055  from the transmission jack ONLY, the J 42055  will provide stability to the driveline components while working on a bench.
  59. Position the driveline on a work bench with the lift device still attached.
  60. Support the driveline support assembly and the differential for additional balance.
  61. Remove the lift device from the driveline.
    Fig 27: Relieving Weight From Transmission Jack
    G01419638Courtesy of GENERAL MOTORS CORP.
  62. Disconnect the transmission oil cooler upper and lower pipe fittings from the transmission, then cap the pipes and plug the fittings to prevent contamination.
    Fig 28: Disconnecting Transmission Oil Cooler Upper And Lower Pipe Fittings From Transmission
    G01419639Courtesy of GENERAL MOTORS CORP.
  63. Remove the transmission oil cooler pipe rear clip.
    Fig 29: Removing Transmission Oil Cooler Pipe Rear Clip
    G01419640Courtesy of GENERAL MOTORS CORP.
  64. Remove the transmission oil cooler pipe middle clip.
  65. Remove the transmission oil cooler pipe front and rear clamp bolts and clamps.
  66. Remove the transmission oil cooler pipes.
    Fig 30: Removing Transmission Oil Cooler Pipe Middle Clip
    G01419641Courtesy of GENERAL MOTORS CORP.
  67. Remove the rear exhaust hanger mounting bolts.
  68. Remove the rear exhaust hangers from the driveline support assembly.
    Fig 31: Removing Rear Exhaust Hanger
    G01419642Courtesy of GENERAL MOTORS CORP.
  69. Remove the transmission to driveline support assembly bolts/studs.
  70. 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.
  71. Slowly slide the driveline support assembly away from the transmission while supporting the transmission torque converter.
  72. Using a strap positioned from side to side, secure the transmission torque converter to the transmission.
    Fig 32: Removing Transmission To Driveline Support Assembly
    G01419643Courtesy of GENERAL MOTORS CORP.
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