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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1166 (Manual Transmission - Mm6/M12) >> Repair Instructions >> Transmission Replacement >> 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.
CAUTION: Refer to BATTERY DISCONNECT CAUTION in Cautions and Notices.
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.
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.
Fig 1: Locating Clearance Between Rear Of Engine & Composite Dash Panel
G01971371Courtesy of GENERAL MOTORS CORP.
NOTE: When tilting down the rear of the driveline, insert a putty knife or similar tool between the shift control bracket on the driveline support assembly and the brake pipe retainer on the driveline tunnel wall to prevent damage.
  1. Disconnect the negative battery cable.
  2. Remove the console. Refer to CONSOLE REPLACEMENT in Instrument Panel, Gages and Console.
  3. Carefully pry off the shift control knob button.
  4. Pry the shift control knob retainer out of the slots and remove the retainer.
    Fig 2: Shift Control Knob Button & Retainer
    G01971372Courtesy of GENERAL MOTORS CORP.
  5. Unscrew the shift control knob.
    Fig 3: Unscrewing Shift Control Knob
    G01971373Courtesy of GENERAL MOTORS CORP.
  6. Grasp the sides of the shift control boot and apply light pressure in toward the shift control lever to begin to release the shift boot retaining tabs from the IP accessory trim plate.
  7. Using light pressure, continue to release the remaining boot retaining tabs.
    Fig 4: Releasing Remaining Boot Retaining Tabs
    G01971374Courtesy of GENERAL MOTORS CORP.
  8. Lift the boot away from the trim plate and remove the boot.
  9. Remove the IP accessory trim plate. Refer to TRIM PLATE REPLACEMENT - INSTRUMENT PANEL (I/P) ACCESSORY in Instrument Panel, Gauges and Console.
    Fig 5: Shift Control Boot
    G01971375Courtesy of GENERAL MOTORS CORP.
  10. Remove the shift control closeout boot retaining nuts.
  11. Remove the shift control closeout boot.
  12. Remove the shift control assembly. Refer to SHIFT CONTROL ASSEMBLY REPLACEMENT .
  13. Remove the left IP lower insulator panel. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT - LEFT in Instrument Panel, Gauges and Console.
    Fig 6: Shift Control Closeout Boot Retaining Nuts & Boot
    G01971376Courtesy of GENERAL MOTORS CORP.
  14. Remove the clutch master cylinder pushrod retainer.
  15. Disconnect the clutch master cylinder pushrod from the clutch pedal.
    Fig 7: Disconnecting Clutch Master Cylinder Pushrod From Clutch Pedal
    G01971377Courtesy of GENERAL MOTORS CORP.
  16. Raise and suitably support the vehicle. Refer to LIFTING AND JACKING THE VEHICLE in General Information.
  17. Remove the clutch actuator cylinder hose from the hose retaining clip (at the rear of the engine).
    Fig 8: Removing Clutch Actuator Cylinder Hose From Hose Retaining Clip
    G01971378Courtesy of GENERAL MOTORS CORP.
  18. Using the J 42371  , depress the white circular release ring on the actuator cylinder hose and simultaneously pull lightly on the master cylinder hose to disconnect.
  19. Protect both hose coupling ends from dirt and damage.
    Fig 9: Hose Coupling Ends
    G01971379Courtesy of GENERAL MOTORS CORP.
  20. Remove the rear tire and wheel assemblies. Refer to TIRE AND WHEEL REMOVAL AND INSTALLATION in Tires and Wheels.
  21. Remove the catalytic converter. Refer to CATALYTIC CONVERTER REPLACEMENT in Engine Exhaust.
  22. Tie off the muffler assemblies to the underbody to support out of the way.
  23. Remove the driveline tunnel closeout panel. Refer to DRIVELINE TUNNEL CLOSEOUT PANEL REPLACEMENT in Propeller Shaft.
    Fig 10: Supporting Muffler Assembly
    G01971380Courtesy of GENERAL MOTORS CORP.
  24. Remove the rear transverse spring. Refer to REAR TRANSVERSE SPRING REPLACEMENT in Rear Suspension.
  25. Support the lower control arm with a straight jack.
  26. Disconnect the outer tie rod end from the suspension knuckle. Refer to TIE ROD REPLACEMENT (OUTER END) or TIE ROD REPLACEMENT (SUSPENSION LINK) in Rear Suspension.
  27. Remove the shock absorber lower mounting bolt.
  28. Disconnect the lower ball joint from the suspension knuckle. Refer to KNUCKLE REPLACEMENT in Rear Suspension.
  29. Remove the straight jack from the control arm.
  30. Repeat steps 25 through 29 for the other side of the vehicle.
    Fig 11: Shock Absorber Lower Mounting Bolt
    G01971381Courtesy of GENERAL MOTORS CORP.
  31. Assemble the J 42055  .
  32. Install the J 42055  to a transmission jack.
  33. Position and firmly secure the J 42055  with the transmission jack to the transmission.
    Fig 12: Transmission Support Fixture
    G01971382Courtesy of GENERAL MOTORS CORP.
  34. Disconnect the wiring harness and brake pipe clip retainers from the rear suspension crossmember.
  35. Remove the differential to transmission lower nut.

    (Removing the nut at this time will aid in separating the differential from the transmission after the driveline has been removed from the vehicle.)

  36. Remove the transaxle mount to rear crossmember nuts.
    Fig 13: Removing Transaxle Mount To Rear Crossmember Nuts
    G01971383Courtesy of GENERAL MOTORS CORP.
  37. Position a transmission jack under the rear suspension crossmember and firmly secure the crossmember to the jack.
  38. Using ONLY HAND TOOLS, remove the rear suspension crossmember retaining nuts.
    Fig 14: Positioning Transmission Jack Under Rear Suspension Crossmember
    G01971384Courtesy of GENERAL MOTORS CORP.
  39. With the aid of an assistant, slowly lower the rear suspension crossmember away from the vehicle frame rails and remove the crossmember.
    Fig 15: Lowering Rear Suspension Crossmember
    G01971385Courtesy of GENERAL MOTORS CORP.
  40. Remove the transaxle mount bracket to differential bolts.
  41. Remove the transaxle mount with bracket.

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

    Fig 16: Removing Transaxle Mount With Bracket
    G01971386Courtesy of GENERAL MOTORS CORP.
  42. Using a pry bar, CAREFULLY release the axle shafts from the differential.
  43. Tie off the axle shafts (1) to the underbody to support out of the way.

    The muffler assembly pipes toward the rear offer a good location to help support the axle shafts (1).

    Fig 17: Supporting Axle Shafts
    G01971387Courtesy of GENERAL MOTORS CORP.
  44. 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 18: Releasing Retainer Securing Wiring Harness To L-Shaped Brackets
    G01971388Courtesy of GENERAL MOTORS CORP.
  45. SLOWLY lower the driveline approximately 5 cm (2 in), while simultaneously adjusting the angle of tilt, in order to access the electrical connectors.
  46. Disconnect the vehicle speed sensor (VSS) electrical connector.
    Fig 19: Disconnecting Vehicle Speed Sensor Electrical Connector
    G01971389Courtesy of GENERAL MOTORS CORP.
  47. Disconnect the wiring harness retainer from the stud at the differential rear cover.
  48. Disconnect the wiring harness retainer clip from the top of the differential.
    Fig 20: Disconnecting Wiring Harness Retainer Clip From Top Of Differential
    G01971390Courtesy of GENERAL MOTORS CORP.
  49. Disconnect the backup lamp switch electrical connector.
    Fig 21: Disconnecting Backup Lamp Switch Electrical Connector
    G01971391Courtesy of GENERAL MOTORS CORP.
  50. Disconnect the reverse lockout solenoid electrical connector.
    Fig 22: Disconnecting Reverse Lockout Solenoid Electrical Connector
    G01971392Courtesy of GENERAL MOTORS CORP.
  51. Disconnect the gear select (skip shift) solenoid electrical connector.
    Fig 23: Disconnecting Gear Select (Skip Shift) Solenoid Electrical Connector
    G01971393Courtesy of GENERAL MOTORS CORP.
  52. Disconnect the transmission fluid temperature sensor electrical connector, if equipped.
    Fig 24: Disconnecting Transmission Fluid Temperature Sensor Electrical Connector
    G01971394Courtesy of GENERAL MOTORS CORP.
  53. Insert a putty knife, or similar tool, between the edge of the shifter bracket on the side of the driveline support assembly and the brake pipe retainer on the wall of the driveline tunnel.
    Fig 25: Inserting Putty Knife Between Edge Of Shifter Bracket & Brake Pipe Retainer
    G01971395Courtesy of GENERAL MOTORS CORP.
  54. 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.)

  55. Release the wiring harness from the harness retainer along the top of the transmission.
  56. Check to be sure that the wiring harness is free from the driveline being removed.
    Fig 26: Lowering Driveline
    G01971396Courtesy of GENERAL MOTORS CORP.
  57. 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.
  58. Remove the five driveline support assembly to engine flywheel housing bolts.
  59. 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.
    Fig 27: Bending Wiring Harness Bracket
    G01971397Courtesy of GENERAL MOTORS CORP.

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

  60. 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 28: Inserting Screwdriver Between Edge Of Driveline Support Assembly & Engine Flywheel Housing
    G01971398Courtesy of GENERAL MOTORS CORP.
  61. Have an assistant guide the front of the driveline during the removal of the driveline from the vehicle.
  62. 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.
  63. SLOWLY lower the driveline completely out of the vehicle.
    Fig 29: Removing Driveline
    G01971399Courtesy of GENERAL MOTORS CORP.
  64. Position the chainfall, or equivalent, of a lift device in a way which will protect the rear exhaust hangers located on the driveline support assembly.
  65. Using the lift device, raise the driveline to relieve the weight from the transmission jack.
  66. Disconnect the J 42055  from the transmission jack ONLY; the J 42055  will provide stability to the driveline components while working on a bench.
  67. Position the driveline on a workbench with the lift device still attached.
  68. Support the driveline support assembly and the differential for additional balance.
  69. Remove the lift device from the driveline.
    Fig 30: Raising Driveline
    G01971400Courtesy of GENERAL MOTORS CORP.
  70. Remove the transmission to driveline support assembly bolts/studs.
  71. 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.
    Fig 31: Removing Transmission To Driveline Support Assembly Bolts/Studs
    G01971401Courtesy of GENERAL MOTORS CORP.
  72. Slowly slide the driveline support assembly away from the transmission while guiding the transmission shift rod through the opening in the driveline support assembly.
    Fig 32: Sliding Driveline Support Assembly Away From Transmission
    G01971402Courtesy of GENERAL MOTORS CORP.
  73. Using a drift or punch, remove the roll pin (1) retaining the transmission shift rod to the transmission shift shaft.
  74. Remove the transmission shift rod.
    Fig 33: Transmission Shift Rod
    G01971403Courtesy of GENERAL MOTORS CORP.
  75. Remove the differential to transmission bolts and nuts.
  76. SLOWLY slide the differential from the transmission.
  77. Remove the transmission from the J 42055  , if necessary.
    Fig 34: Removing Differential From Transmission
    G01971404Courtesy of GENERAL MOTORS CORP.
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