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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 716 (Manual Transmission - ZF S6-650) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2002 GMC Sierra, 2002 GMC Cab & Chassis Sierra, 2002 Chevrolet Silverado, and 2002 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the insulator to the top of the transmission.
  2. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
  3. Rotate the transmission clockwise onto the clutch hub splines.
  4. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
  5. If equipped with a 8.1L engine, install the transmission studs. Tighten the transmission studs to 50 N.m (37 lb ft).
  6. Install the insulator to the top of the transmission.
  7. Slowly feed the clutch hydraulic hose towards the clutch master cylinder.
  8. Rotate the transmission clockwise onto the clutch hub splines.
  9. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission
  10. If equipped with a 6.6L engine, install the transmission bolts/studs. Tighten the transmission bolts/studs to 50 N.m (37 lb ft).
  11. Install the transmission support.
  12. Remove the transmission jack.
  13. Install the exhaust pipe hanger bracket and bolts. Tighten the exhaust pipe hanger bracket bolts to 12 N.m (106 lb in).
  14. Install the starter.
  15. If equipped with 4WD, install the vent hose clip (1) to the fuel feed/return bracket.
  16. Install the vent hose clip and nut. Tighten the vent hose clip nut to 25 N.m (18 lb ft).
  17. If equipped with 4WD, install the vent hose clip to the bracket.
  18. Install the fuel lines to the fuel feed/return brackets.
  19. Position the harness.
  20. Install the oxygen sensors connectors (1,3) to the fuel feed/return hose clip and transmission bracket.
  21. Install the PTO connector to the fuel feed/return bracket.
  22. Install the engine harness clips (6) to the fuel feed/return brackets.
  23. If equipped with a 8.1L engine, connect the following electrical connectors:
    • PTO (2), if connected
    • Oxygen sensors (1, 3)
    • Backup lamp switch (4)
    • VSS (5)
  24. Install the fuel lines to the fuel feed/return brackets.
  25. Position the harness.
  26. Install the PTO connector to the fuel feed/return bracket.
  27. Install the engine harness clips (1) to the fuel feed/return brackets.
  28. If equipped with a 6.6L engine, connect the following electrical connectors:
    • PTO (2), if connected
    • Backup lamp switch (3)
    • VSS (4)
  29. Connect the clutch actuator cylinder line retaining clips.

    Important:  Improper connection may cause the quick connect from locking properly. Before pushing in the clutch pedal fully, check with light pressure. If pedal is hard recheck the connection.

  30. Connect the clutch actuator cylinder hydraulic hose quick connect from the master cylinder.
  31. If equipped with 4WD, install the transfer case. Refer to TRANSFER CASE ASSEMBLY REPLACEMENT - NVG263-NP (SELECTABLE) or TRANSFER CASE ASSEMBLY REPLACEMENT - NVG261-NP2 (TWO SPEED MANUAL) .
  32. If vehicle is a 2WD, install the rear propeller shaft, Refer to PROPELLER SHAFT REPLACEMENT - ONE PIECE or PROPELLER SHAFT REPLACEMENT - TWO PIECE .
  33. Lower the vehicle.
  34. Install the shift lever. Refer to Shift Lever Assembly Replacement .
  35. Fill the transmission with fluid.
  36. Bleed the clutch hydraulic system, if necessary. Refer to BLEEDING .
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