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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1459 (Automatic Transaxle - AF33-5 (Removal & Installation, Service & Overhaul)) >> Repair Instructions >> Transmission Replacement >> Removal Procedure >> Installation Procedure

Installation Procedure

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    Fig 1: Installing Wheel Drive Shaft Retaining Ring
    GM928989Courtesy of GENERAL MOTORS CORP.
    CAUTION: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
  1. Position the vehicle on a hoist and raise the vehicle.
  2. Install new stub shaft retaining rings.
    3. Fig 2: View Of PTU
    GM945606Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the power take-off unit (PTU) bolts and the PTU unit to the transaxle.

    Tighten:  Tighten the PTU bolts to 60 N.m (44 lb ft)

    4. Fig 3: View Of Stub Shaft
    GM993576Courtesy of GENERAL MOTORS CORP.
  4. Install stub shaft into transaxle.
  5. Install PTU vent hose.
  6. With the transaxle supported, carefully raise the transaxle. It may be helpful to lower the vehicle down around the transaxle.
  7. Carefully assemble the engine to the transaxle.
    8. Fig 4: Removing/Installing Transaxle
    GM989323Courtesy of GENERAL MOTORS CORP.
  8. Install the upper and lower transaxle-to-engine bolts.

    Tighten:  Tighten the transaxle-to-engine (18 mm) bolts to 75 N.m (55 lb ft)

    Tighten:  Tighten the transaxle-to-engine (15 mm) bolts to 50 N.m (37 lb ft)

  9. Install the engine-to-transaxle bolt located above the PTU.

    Tighten:  Tighten the engine-to-transaxle bolt to 75 N.m (55 lb ft)

    10. Fig 5: View Of PTU-To-Engine Bracket Bolts
    GM988424Courtesy of GENERAL MOTORS CORP.
  10. Install PTU-to-engine bracket assembly.

    Tighten:  Tighten the PTU-to-engine bracket bolts to 60 N.m (44 lb ft)

  11. Install exhaust downpipe.
    12. Fig 6: View Of Torque Converter-To-Flexplate Bolts
    GM989287Courtesy of GENERAL MOTORS CORP.
  12. Rotate the crank and align the net hole of the flexplate through the starter opening.
  13. Install the torque converter-to-flexplate bolts through the starter hole.

    Tighten:  Tighten the converter-to-flexplate bolts to 60 N.m (44 lb ft)

  14. Install the starter and the starter bolts

    Tighten:  Tighten the starter bolts to 40 N.m (30 lb ft)

  15. Install starter wiring harness.

    Tighten:  Tighten the B+ Cable-to-starter nut to 10 N.m (89 lb in)

    Tighten:  Tighten the S-terminal nut to 5 N.m (44 lb in)

    16. Fig 7: Installing Wheel Drive Shaft On The Output Shaft
    GM928914Courtesy of GENERAL MOTORS CORP.
  16. Install the right axle shaft to PTU stub shaft.
    17. Fig 8: View Of Left Axle Shaft Retaining Ring
    GM931472Courtesy of GENERAL MOTORS CORP.
  17. Install a new retaining ring on the left axle shaft.
    18. Fig 9: Installing SA91112T
    GM934583Courtesy of GENERAL MOTORS CORP.
  18. Install the SA91112T  inside the left axle seal
    19. IMPORTANT: Do not damage the left axle seal
  19. Lubricate the axle with transaxle fluid.
  20. Carefully install the left axle shaft into the transaxle.
  21. Remove the SA91112T  after the splines clear the seal protector, but before the axle shaft is fully installed.
  22. Push left axle shaft all the way into the transaxle.
    23. Fig 10: Removing/Installing Frame To Body Bolts
    GM933087Courtesy of GENERAL MOTORS CORP.
  23. With the cradle on a support table, install the cradle and the cradle fasteners carefully into the vehicle.

    Tighten:  Tighten the frame-to-body bolts to 155 N.m (114 lb ft)

  24. Remove the support table.
    25. Fig 11: View Of Front Pitch Restrictor Through-Bolt
    GM993567Courtesy of GENERAL MOTORS CORP.
  25. Install the rear pitch restrictor through-bolt.

    Tighten:  Tighten the rear pitch restrictor bolt to 110 N.m (81 lb ft)

    26. Fig 12: Removing/Installing Front Pitch Restrictor
    GM993507Courtesy of GENERAL MOTORS CORP.
  26. Install the front pitch restrictor bolts, through-bolt and front pitch restrictor.

    Tighten:  Tighten the Front pitch restrictor bolts to 50 N.m (37 lb ft)

    Tighten:  Tighten the Front pitch restrictor through-bolts to 110 N.m (81 lb ft)

    27. Fig 13: View Of Tie Rod, Knuckle & Tapered Ball Stud
    GM891579Courtesy of GENERAL MOTORS CORP.
  27. Use the J 44015  to install the knuckle to the outer tie rod.
    28. Fig 14: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  28. Install the outer tie rod-to-knuckle nut.

    Tighten:  Tighten the rod-to-knuckle nut to 50 N.m (37 lb ft)

    29. Fig 15: View Of Lower Ball Joint Stud Cotter Pin & Nut
    GM929893Courtesy of GENERAL MOTORS CORP.
  29. Install the lower control arm ball stud-to-knuckle.
    30. IMPORTANT: Tighten the nut one additional flat to align cotter pin hole if necessary.
  30. Install the nut and new cotter pin.

    Tighten:  Tighten the lower control arm nut to 110 N.m (81 lb ft)+150°

  31. Install the rack and pinion bolts to the cradle.

    Tighten:  Tighten the rack and pinion bolts to 110 N.m (81 lb ft)

    32. Fig 16: View Of Stabilizer Bar Clamps, Bushings & Bolts
    GM929945Courtesy of GENERAL MOTORS CORP.
  32. Connect the lower stabilizer nut to the cradle on both sides of the vehicle.

    Tighten:  Tighten the lower stabilizer nut to 65 N.m (48 lb ft)

    33. Fig 17: Removing/Installing Drive Shaft
    GM993228Courtesy of GENERAL MOTORS CORP.
  33. Install drive shaft to PTU.

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

  34. If the transaxle being installed is not new, then the transaxle oil cooler line seals must be removed and replaced. Refer to Transaxle Oil Cooler Line Seals removal and installation procedure in this service manual.
    35. Fig 18: View Of Transaxle Oil Cooler Lines
    GM945444Courtesy of GENERAL MOTORS CORP.
  35. Connect the transaxle cooler lines and the nut to the transaxle.

    Tighten:  Tighten the transaxle cooler line nut to 7 N.m (62 lb in)

    36. Fig 19: View of Air Deflector Replacement - Front Bumper Fascia
    GM930960Courtesy of GENERAL MOTORS CORP.
  36. Install the front air dam deflector-to-cradle pushpins.
    37. Fig 20: View of Engine Splash Shield
    GM929650Courtesy of GENERAL MOTORS CORP.
  37. Install the left-side and right-side inner splash shields.
    38. Fig 21: Removing & Installing Tire & Wheel Assembly
    GM891537Courtesy of GENERAL MOTORS CORP.
  38. Install the left-side and right-side wheel and tire assemblies.

    Tighten the bolts in a criss-cross pattern.

    Tighten:  Tighten the wheel nuts to 125 N.m (92 lb ft)

  39. Lower the vehicle.
    40. Fig 22: View Of Upper Left-Hand Transaxle Mount Bolts
    GM991548Courtesy of GENERAL MOTORS CORP.
  40. Install the upper left-hand transaxle mount and bolts.

    Tighten:  Tighten the upper left-hand transaxle mount bolts to 50 N.m (37 lb ft)

    41. Fig 23: View Of Fluid Level Indicator Assembly
    GM991083Courtesy of GENERAL MOTORS CORP.
  41. Install the fluid level indicator assembly.

    Tighten:  Tighten the fluid level indicator bolt to 12 N.m (9 lb ft)

    42. Fig 24: Engine Support Tool
    GM959655Courtesy of GENERAL MOTORS CORP.
  42. Remove the engine support tool.
  43. Remove the tie straps from the radiator.
  44. Install the positive battery cable to the transaxle stud.
  45. Install the harness to the transaxle range switch stud and the control cable bracket.
  46. Connect the input and output speed sensor harness connectors.
  47. Connect the transaxle range switch harness connectors.
    48. Fig 25: View Of Control Cable
    GM978330Courtesy of GENERAL MOTORS CORP.
  48. Connect the control cable to the control cable bracket.
  49. Connect the control cable to the transaxle range switch assembly lever.
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