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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 853 (Automatic Transaxle Diagnosis, Service & Repair - 4T65-E) >> Repair Instructions >> Oil Pan Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Do NOT use any type of grease to retain parts during the assembly of this unit. Using greases other than the recommended assembly lube changes the transaxle fluid characteristics. Using greases other than the recommended assembly lube causes undesirable shift conditions and/or filter clogging. Use TRANSJEL™: J 36850 or equivalent during the assembly of this unit
  1. Raise and support the vehicle.
  2. Place a drain pan under the transaxle bottom oil pan.
  3. Remove the oil pan bolts (23) from the front.
  4. Remove the oil pan bolts from the sides.
  5. Loosen the rear oil pan bolts approximately four turns.
    NOTE: Ensure care is taken NOT to damage the mating surfaces of the oil pan and of the case or oil leaks may occur
  6. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose.
  7. Allow the fluid to drain.
  8. Remove the remaining oil pan bolts (23).
  9. Remove the oil pan (24).
  10. Remove the oil pan gasket (25).
  11. Inspect the oil pan and the filter screen for the following foreign material:
    • Inspect for metal particles.
    • Inspect for clutch facing material.
    • Inspect for rubber particles.
    • Inspect for engine coolant.
  12. Determine the source of the contamination if foreign material is evident.
  13. Correct the source of the contamination.
    Fig 1: Removing Oil Pan (1 Of 5)
    G01501950Courtesy of GENERAL MOTORS CORP.
  14. Inspect the oil pan flange (1) for distortion.
  15. Replace the oil pan (1) if bent or distorted. Do not attempt to straighten.
    Fig 2: Removing Oil Pan (2 Of 5)
    G01501951Courtesy of GENERAL MOTORS CORP.
  16. Inspect the washers on the bolts when service requires the removal of the bottom oil pan.
    Fig 3: Removing Oil Pan (3 Of 5)
    G01501952Courtesy of GENERAL MOTORS CORP.
  17. Install a new bolt and washer assembly if the washer is inverted.
    Fig 4: Removing Oil Pan (4 Of 5)
    G01501953Courtesy of GENERAL MOTORS CORP.
  18. Inspect the oil pan (24) for the following conditions:
    • A damaged sealing surface
    • A dented or cracked bottom surface
  19. Inspect the oil pan gasket (25) for the following conditions:
    • A bent or damaged seal core
    • A damaged rubber seal surface
    • A damaged gasket
  20. Inspect the oil pan magnet (26) for the following conditions:
    • Damage
    • Misalignment
  21. Clean the oil pan, the gasket and the magnet in order to remove any sediment.
    Fig 5: Removing Oil Pan (5 Of 5)
    G01501954Courtesy of GENERAL MOTORS CORP.
    NOTE: Ensure the oil pan and the case flanges are dry and are free of any oil film or leakage may result
  22. Use solvent to clean the case.
  23. Air dry the case.
  24. Use solvent to clean the oil pan gasket surfaces.
  25. Air dry the oil pan gasket surfaces.
  26. Ensure all traces of the old gasket material are removed.
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