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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 813 (Automatic Transmission - 4L80-E/4L85-E (Service & Replacement)) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2003 GMC Yukon XL, 2003 Chevrolet Suburban, and 2003 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the transmission to the vehicle.
  2. Raise the transmission into place and remove the J 21366  from the transmission.
  3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the transmission studs.

    Tighten 

    Tighten the studs to 50 N.m (37 lb ft).

    Fig 1: Installing Transmission Studs
    G02112327Courtesy of GENERAL MOTORS CORP.
  5. Install the stud on the left side of the transmission.

    Tighten 

    Tighten the stud to 50 N.m (37 lb ft).

    Fig 2: Installing Stud On Left Side Of Transmission
    G02112328Courtesy of GENERAL MOTORS CORP.
  6. Remove the plugs from the transmission oil cooler line fittings.
  7. Connect the transmission oil cooler lines. Refer to TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING  .
    Fig 3: Connecting Transmission Oil Cooler Lines
    G02112329Courtesy of GENERAL MOTORS CORP.
  8. If equipped with a 6.0L or 8.1L engine, install the exhaust hanger mounting bracket and bolts.

    Tighten 

    Tighten the bolts to 12 N.m (106 lb in).

    Fig 4: Installing Exhaust Hanger Mounting Bracket Bolts & Bracket
    G02112330Courtesy of GENERAL MOTORS CORP.
  9. If equipped with a 6.0L engine, install the exhaust hanger mounting bracket and bolts.

    Tighten 

    Tighten the bolts to 12 N.m (106 lb in).

    Fig 5: Installing Exhaust Hanger Mounting Bracket & Bolts
    G02112331Courtesy of GENERAL MOTORS CORP.
  10. Align the torque converter to the flywheel.
  11. Install the torque converter bolts.

    Tighten 

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

  12. Install the flywheel inspection cover.

    Tighten 

    Tighten the bolts to 33 N.m (24 lb ft).

    Fig 6: Installing Torque Converter & Bolts
    G02112332Courtesy of GENERAL MOTORS CORP.
  13. Connect the following electrical connectors:
    • Input speed sensor (1)
    • Output speed sensor (3)
    • PNP switch (5)
    • Transmission (4)
  14. 14. Connect the HO2S electrical connector.
  15. Connect the wire harness clip (2) to the bracket on the left side of the transmission.
    Fig 7: Connecting Wire Harness Clip To Bracket
    G02112333Courtesy of GENERAL MOTORS CORP.
  16. Depress the tangs and install the cable to the bracket.
  17. Install the range selector cable end (2) to the transmission range selector lever ball stud (1).
    Fig 8: Installing Range Selector Cable End To Transmission Range Selector Lever Ball Stud
    G02112334Courtesy of GENERAL MOTORS CORP.
  18. Ensure the transmission manual shaft is positioned in mechanical park.
  19. Install the retainer that secures the cable to the bracket.
    Fig 9: Installing Retainer That Secures Cable To Bracket
    G02112335Courtesy of GENERAL MOTORS CORP.
  20. Install the transmission mount and bolts.

    Tighten 

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

  21. Install the transfer case, if equipped. Refer to:
  22. Install the exhaust manifold pipe. Refer to EXHAUST MANIFOLD PIPE REPLACEMENT (6.0L AND 8.1L ENGINES) in Engine Exhaust.
    Fig 10: Installing Transmission Mount & Bolts
    G02112336Courtesy of GENERAL MOTORS CORP.
  23. Install the transmission support.
  24. Install the transmission support bolts/nuts.

    Tighten 

    Tighten the bolts to 95 N.m (75 lb ft).

    Fig 11: Installing Transmission Support & Bolts/Nuts
    G02112337Courtesy of GENERAL MOTORS CORP.
  25. Install the transmission mount nuts.

    Tighten 

    Tighten the nut to 50 N.m (37 lb ft).

  26. Remove the support from the transmission.
  27. Install the rear propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT - REAR in Propeller Shaft.
  28. Fill the transmission fluid. Refer to AUTOMATIC TRANSMISSION FLUID/FILTER REPLACEMENT  .
  29. Connect the negative battery cable. Refer to BATTERY DISCONNECT CAUTION in Engine Electrical.
  30. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to TRANSMISSION FLUID CHECKING PROCEDURE  .
    Fig 12: Installing Transmission Support & Bolts/Nuts
    G02112338Courtesy of GENERAL MOTORS CORP.
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