LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 939 (Manual Transmission -- ZF S6-650) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra and 2004 Chevrolet 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.
    Fig 1: Installing Transmission To Engine
    GM776275Courtesy of GENERAL MOTORS CORP.
  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.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. If equipped with a 8.1L engine, install the transmission studs.

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

    6. Fig 2: Installing The Insulator To The Top Of The Transmission
    GM776274Courtesy of GENERAL MOTORS CORP.
  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:  Tighten the bolts/studs to 50 N.m (37 lb ft).

  11. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
  12. Remove the transmission jack.
    13. Fig 3: Installing The Exhaust Pipe Hanger Bracket And Bolts
    GM694241Courtesy of GENERAL MOTORS CORP.
  13. Install the exhaust pipe hanger bracket and bolts.

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

  14. Install the starter. Refer to Starter Motor Replacement (4.3L Engine) or Starter Motor Replacement (4.8L, 5.3L, and 6.0L Engines) or Starter Motor Replacement (6.6L (LB7) Engine) or Starter Motor Replacement (6.6L (LLY) Engine) or Starter Motor Replacement (8.1L Engine) in Engine Electrical.
    15. Fig 4: Installing The Vent Hose Clip To The Fuel Feed/Return Bracket (4WD)
    GM776223Courtesy of GENERAL MOTORS CORP.
  15. If equipped with 4WD, install the vent hose clip (1) to the fuel feed/return bracket.
    16. Fig 5: Installing The Vent Hose Clip And Nut
    GM775346Courtesy of GENERAL MOTORS CORP.
  16. Install the vent hose clip and nut.

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

  17. If equipped with 4WD, install the vent hose clip to the bracket.
    18. Fig 6: Installing The Fuel Lines To The Fuel Feed/Return Brackets
    GM776054Courtesy of GENERAL MOTORS CORP.
  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. Fig 7: Installing The Fuel Lines To The Fuel Feed/Return Brackets
    GM776052Courtesy of GENERAL MOTORS CORP.
  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. Fig 8: Connecting The Clutch Actuator Cylinder Line Retaining Clips
    GM689678Courtesy of GENERAL MOTORS CORP.
    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.
  29. Connect the clutch actuator cylinder line retaining clips.
  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 in Transfer Case - NVG263-NP1 (Selectable) or Transfer Case Assembly Replacement in Transfer Case - NVG261-NP2 (Two Speed Manual).
  32. If vehicle is a 2WD, install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece orPropeller Shaft Replacement - Two Piece in Propeller Shaft.
  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 Hydraulic Clutch Bleeding in Clutch.
scientia non olet · About LEMON Manuals