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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 >> Removal Procedure

Removal 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. Shift the transmission into 3rd or 4th gear.
  2. Remove the shift lever. Refer to Shift Lever Assembly Replacement .
  3. Raise and suitably support the vehicle.

    Important:  The clutch actuator cylinder hose can remain attached to the clutch actuator. Disconnecting the hose from the clutch actuator cylinder will cause the fluid to drain from the hydraulic system.

    4. Fig 1: Disconnecting Hose From Clutch Actuator Cylinder
    G01715509Courtesy of GENERAL MOTORS CORP.
  4. Drain the transmission fluid.
  5. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - ONE PIECE or PROPELLER SHAFT REPLACEMENT - TWO PIECE .
  6. If equipped with 4 wheel drive (4WD), remove the transfer case. Refer to TRANSFER CASE ASSEMBLY REPLACEMENT - NVG263-NP (SELECTABLE) or TRANSFER CASE ASSEMBLY REPLACEMENT - NVG261-NP2 (TWO SPEED MANUAL) .
  7. Disconnect the clutch actuator cylinder hydraulic hose quick connect at the master cylinder.
  8. Disconnect the clutch actuator cylinder line retaining clips.
  9. If equipped with a 6.6L engine, disconnect the following electrical connectors:
    • Power take-off (PTO) (2), if connected
    • Backup lamp switch (3)
    • Vehicle speed sensor (VSS) (4)
  10. Remove the engine harness clips (1) from the fuel feed/return brackets.
  11. Remove the PTO connector from the fuel feed/return bracket.
  12. Reposition the harness.
  13. Remove the fuel lines from the fuel feed/return brackets.
  14. If equipped with a 8.1L engine, disconnect the following electrical connectors:
    • Power take-off (PTO) (2), if connected
    • Oxygen sensors (1,3)
    • Backup lamp switch (4)
    • VSS (5)
  15. Remove the engine harness clips (6) from the fuel feed/return brackets.
  16. Remove the PTO connector from the fuel feed/return bracket.
  17. Remove the oxygen sensors connectors (1,3) from the fuel feed/return hose clip and transmission bracket.
  18. Reposition the harness.
  19. Remove the fuel lines from the fuel feed/return brackets.
    Fig 2: Fuel Feed/Return Bracket
    G01715511Courtesy of GENERAL MOTORS CORP.
  20. If equipped with 4WD, remove the vent hose clip from the bracket.
  21. Remove the vent hose clip nut and clip.
    Fig 3: Vent Hose Clip Nut & Clip
    G01715512Courtesy of GENERAL MOTORS CORP.
  22. If equipped with 4WD, remove the vent hose clip (1) from the fuel feed/return bracket.
    23. Fig 4: Vent Hose Clip
    G01715513Courtesy of GENERAL MOTORS CORP.
  23. Remove the starter.
  24. Remove the exhaust pipe hanger bracket bolts and bracket.
  25. Support the transmission with a suitable transmission jack.
  26. Remove the transmission support.
    Fig 5: Transmission Support
    G01715514Courtesy of GENERAL MOTORS CORP.
  27. If equipped with a 6.6L engine, remove the transmission bolts/studs.
  28. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  29. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  30. Remove the insulator from the top of the transmission.
  31. If equipped with a 8.1L engine, remove the transmission studs.
  32. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  33. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  34. Remove the insulator from the top of the transmission.
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