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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 973 (Automatic Transmission - ALLISON (Introduction, Service & Replacement)) >> Repair Instructions >> Transmission Replacement (With 6.6L Engine) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: If replacing a failed transmission, the "FastLearn" (adapt) procedure must be performed. This can be done in one step using a scan tool. If this procedure is not done, the transmission control module's (TCM's) adaptive values will still be at the settings that it learned for the old transmission, and will be in slow adaptive mode. Under these conditions, it would take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission.
  1. Disconnect both of the negative battery cables. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  2. Remove the transmission fluid level indicator.
  3. Raise the vehicle until the right front wheel and tire can be removed. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the right front wheel and tire.
  5. Remove the right front wheel house inner panel retainers (2).
    Fig 1: View Of Wheelhouse Panel & Push-In Retainers
    GM401885Courtesy of GENERAL MOTORS CORP.
  6. Disconnect any harness retainers attached to the inner panel.
  7. Remove the inner panel (1).
    8. Fig 2: Removing The Positive Battery Cable Nut And Cable From The Starter (With 6.6L Engine)
    GM674619Courtesy of GENERAL MOTORS CORP.
  8. Remove the positive battery cable nut and cable from the starter.
  9. Remove the solenoid nut and wire from the starter.
    10. Fig 3: Removing The Starter Motor Bolts (With 6.6L Engine)
    GM660305Courtesy of GENERAL MOTORS CORP.
  10. Remove the starter motor bolts and reposition the starter.
    11. Fig 4: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  11. Remove the engine protection shield bolts and shield.
  12. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts through the starter opening. Have an assistant rotate the engine while aligning the bolts.
    IMPORTANT: Rotate the engine clockwise ONLY, rotating the engine counterclockwise may loosen the crankshaft balancer bolt.
    Fig 5: Torque Converter Bolts (With 6.6L Engine)
    GM702519Courtesy of GENERAL MOTORS CORP.
  13. Remove the torque converter bolts.
  14. Completely raise the vehicle.
  15. Drain the transmission fluid.
    16. Fig 6: Disconnecting The Shift Cable From The Selector Lever Ball Stud (With 6.6L Engine)
    GM686691Courtesy of GENERAL MOTORS CORP.
  16. Disconnect the shift cable from the selector lever ball stud (5) and remove the cable from the bracket (3).
    17. Fig 7: Removing The Shift Cable Bracket Bolts And Bracket (With 6.6L Engine)
    GM686689Courtesy of GENERAL MOTORS CORP.
  17. Remove the shift cable bracket bolts and bracket (2) from the transmission.
  18. Reposition the bracket with the cable attached off to the side.
  19. Remove the fuel line retainer (1) bolts on the left side of the transmission.
    Fig 8: Removing The Fuel Line Retainer Bolts (With 6.6L Engine)
    GM702521Courtesy of GENERAL MOTORS CORP.
    20. Fig 9: Removing The Fuel Line Bracket Nut (With 6.6L Engine)
    GM702523Courtesy of GENERAL MOTORS CORP.
  20. Remove the fuel line bracket nut from the converter housing stud.
    21. Fig 10: Disconnecting The Turbine Speed Sensor And Input Speed Sensor Electrical Connectors (With 6.6L Engine)
    GM702774Courtesy of GENERAL MOTORS CORP.
  21. Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors.
  22. Disconnect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4 wheel drive (4WD), the output speed sensor is located on the transfer case and will be disconnected later.
    23. Fig 11: Disconnecting The Transmission Main Electrical Connector (With 6.6L Engine)
    GM659284Courtesy of GENERAL MOTORS CORP.
  23. Disconnect the transmission main electrical connector. J 44257  may be used, but is not required.
  24. Disconnect the park/neutral position (PNP) switch electrical connector.
    Fig 12: Exhaust Hanger Bolts (With 6.6L Engine)
    GM694239Courtesy of GENERAL MOTORS CORP.
  25. Remove the exhaust hanger bolts and reposition the hanger.
  26. If the vehicle is a 2 wheel drive (2WD), remove the propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece in Propeller Shaft.
    27. Fig 13: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  27. Support the transmission with a transmission jack.
  28. If the vehicle is a 2WD, remove the transmission mount nuts.
    29. Fig 14: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  29. If the vehicle is a 2WD, remove the transmission support bracket bolts.
  30. If the vehicle is a 2WD, remove the transmission support bolts and nuts.
    31. Fig 15: Locating Transmission Mount Bolts
    GM702771Courtesy of GENERAL MOTORS CORP.
  31. Remove the transmission mount bolts (1).
  32. Remove the transmission mount.
  33. If the vehicle is equipped with 4WD, remove the transfer case.
  34. Reposition any wiring harness branches out of the way.
    35. Fig 16: Securing Safety Chain Around The Transmission (With 6.6L Engine)
    GM702527Courtesy of GENERAL MOTORS CORP.
  35. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other related components.
    36. Fig 17: Disconnecting The Transmission Oil Cooler Lines From The Transmission (With 6.6L Engine)
    GM686709Courtesy of GENERAL MOTORS CORP.
  36. Disconnect the transmission oil cooler lines (1, 2) from the transmission.
  37. Plug the transmission oil cooler line fittings in the transmission case, if necessary.
  38. If the vehicle is equipped with a power take off (PTO) unit, disconnect and/or remove any necessary components to facilitate transmission removal.
    39. Fig 18: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  39. Remove the transmission fill tube nuts from the converter housing studs.
    40. Fig 19: Removing The Wire Harness/Vent Tube Bracket Nut From The Converter Housing Stud (With 6.6L Engine)
    GM702529Courtesy of GENERAL MOTORS CORP.
  40. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the bracket.
    41. Fig 20: Removing The Remaining Converter Housing Bolts And Studs (With 6.6L Engine)
    GM686685Courtesy of GENERAL MOTORS CORP.
  41. Remove the remaining converter housing bolts and studs.
  42. Separate the transmission from the engine.
    43. Fig 21: Installing J 21366 To The Converter Housing (With 6.6L Engine)
    GM702530Courtesy of GENERAL MOTORS CORP.
  43. Install J 21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
  44. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
  45. Remove the J 21366.
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