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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1308 (Automatic Transmission - 4L60-E/4L65-E (Introduction, Service & Replacement)) >> Repair Instructions >> Oil Cooler Line Replacement (Front) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Battery Negative Cable
    GM513056Courtesy of GENERAL MOTORS CORP.
  1. Position the front wheels straight ahead, remove the ignition key to lock the steering column.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  3. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Place a drain pan under the vehicle to catch any fluid.
    6. Fig 2: TOC Connection & J 44827
    GM795414Courtesy of GENERAL MOTORS CORP.
  6. Reposition the plastic retainer, in order to gain access to the lower transmission oil cooler (TOC) connection.
  7. Using J 44827  , disconnect the lower TOC line from the oil cooler. See Special Tools and Equipment .
  8. Lower the vehicle; leave the vehicle on the hoist.
  9. Reposition the plastic retainer, in order to gain access to the upper TOC connection.
  10. Using J 44827  disconnect the upper TOC line from the oil cooler. See Special Tools and Equipment .
  11. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 5.7L.
  12. Remove the upper and lower radiator support. Refer to Radiator Support Replacement in Engine Cooling.
    13. Fig 3: Front Evaporator Tube & Condenser Bolt
    GM297294Courtesy of GENERAL MOTORS CORP.
  13. Recover the refrigerant from the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
  14. Remove the front evaporator tube to condenser bolt.
    IMPORTANT: Cap or tape the opening in the front evaporator tube and condenser immediately to prevent contamination.
  15. Disconnect the front evaporator tube from the condenser.
    16. Fig 4: Disassembling/Reassembling A/C Line Fittings
    GM297225Courtesy of GENERAL MOTORS CORP.
  16. Using a back-up wrench on the condenser fitting (2), loosen the compressor hose fitting (1) from the condenser.
    17. Fig 5: Compressor Hose & Condenser
    GM82073Courtesy of GENERAL MOTORS CORP.
  17. Disconnect the compressor hose from the condenser.
  18. Discard the O-ring seal and cap or tape the compressor hose and condenser openings.
    19. Fig 6: Surge Tank Upper Hose & Radiator Inlet
    GM179287Courtesy of GENERAL MOTORS CORP.
  19. Using J 38185  , release and reposition the coolant surge tank upper hose clamp away from the radiator inlet.
  20. Separate the surge tank upper hose from the radiator inlet.
    21. Fig 7: Radiator Inlet Hose & Radiator Inlet
    GM64025Courtesy of GENERAL MOTORS CORP.
  21. Using J 38185  , release and reposition the radiator inlet hose clamp away from the radiator inlet.
  22. Separate the radiator inlet hose from the radiator inlet.
    23. Fig 8: Radiator Outlet Hose & Radiator Outlet
    GM64026Courtesy of GENERAL MOTORS CORP.
  23. Using J 38185  , release and reposition the radiator outlet hose clamp away from the radiator outlet.
  24. Separate the radiator outlet hose from the radiator outlet.
    25. Fig 9: A/C Condenser With Radiator Forward & Assembly
    GM173673Courtesy of GENERAL MOTORS CORP.
  25. Carefully pivot the A/C condenser with the radiator forward and tie off to support the assembly.
    26. Fig 10: Intermediate Shaft Lower Coupling & Bolt
    GM70108Courtesy of GENERAL MOTORS CORP.
  26. Remove the steering column intermediate shaft lower coupling shield.
  27. Match-mark the intermediate shaft lower coupling to the power steering (PS) gear to ensure correct orientation upon installation.
  28. Remove the intermediate shaft lower coupling bolt.
  29. Disconnect the intermediate shaft lower coupling from the PS gear.

    Slide the intermediate shaft lower coupling off of the PS gear steering shaft.

    30. Fig 11: PS Cooler & Retaining Bolts
    GM65353Courtesy of GENERAL MOTORS CORP.
  30. Remove the PS cooler retaining bolts.
    31. Fig 12: BPMV Bracket, PS Gear, Mounting Bolts & Nuts
    GM65352Courtesy of GENERAL MOTORS CORP.
  31. Remove the brake pressure modulator valve (BPMV) bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Antilock Brake System.
  32. Remove the PS gear mounting bolts and nuts.
  33. Release the PS gear and cooler from the front suspension crossmember, then slave the gear and cooler forward.
  34. Remove the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in Heating, Ventilation, and Air Conditioning.
  35. Remove the generator. Refer to Generator Replacement in Engine Electrical.
  36. Install the J 41803  and the J 28467-B  in order to support the engine.
  37. Remove the right hand engine mount (and bracket). Refer to Engine Mount Replacement - Right in Engine Mechanical - 5.7L.
    38. Fig 13: TOC Front Pipe & Front Clip
    GM71420Courtesy of GENERAL MOTORS CORP.
  38. Remove the TOC front pipe front clip.
  39. Raise the vehicle.
    40. Fig 14: TOC Front Pipe, Front Retaining Clamp & Bolt
    GM71419Courtesy of GENERAL MOTORS CORP.
  40. Remove the TOC front pipe front retaining clamp bolt and retaining clamp.
    41. Fig 15: Locating Cooler Fittings
    GM71418Courtesy of GENERAL MOTORS CORP.
  41. Remove the TOC front pipe rear retaining clamp bolt and retaining clamp.
  42. Disconnect the TOC front pipe fittings from the junction fittings at the engine flywheel housing, then cap the pipe fittings and plug the junction fittings to prevent contamination.
  43. Lower the vehicle; leave the vehicle slightly above the ground.
  44. Finesse the TOC front pipes out of the vehicle (through the top).
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