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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 8.1L (L18) Engine) >> Installation Procedure

Installation 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.
  1. Install J 21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
    Fig 1: Installing J 21366 To The Converter Housing (With 8.1L (L18) Engine)
    GM702530Courtesy of GENERAL MOTORS CORP.
  2. Raise the transmission into place while simultaneously installing the fill tube.
  3. Remove the J 21366.
    4. IMPORTANT: Do not install the transmission by drawing it to the engine using the studs and bolts.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Align the transmission with the engine using the alignment dowels located at the rear of the engine.
  5. Install the converter housing bolts and studs.

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

    Fig 2: Converter Housing Bolts And Studs (With 8.1L (L18) Engine)
    GM744182Courtesy of GENERAL MOTORS CORP.
    6. Fig 3: Installing The Wire Harness/Vent Tube Bracket Nut To The Converter Housing Stud (With 8.1L (L18) Engine)
    GM702529Courtesy of GENERAL MOTORS CORP.
  6. Position the wire harness/vent tube bracket and install the wire harness/vent tube bracket nut to the converter housing stud.

    Tighten:  Tighten the nut to 18 N.m (13 lb ft).

    7. Fig 4: Installing Fuel Line Bracket Nut To The Converter Housing Stud (With 8.1L (L18) Engine)
    GM702523Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel line bracket nut to the converter housing stud.

    Tighten:  Tighten the nut to 18 N.m (13 lb ft).

    8. Fig 5: View Of Fill Tube To Bellhousing Nuts
    GM702776Courtesy of GENERAL MOTORS CORP.
  8. Install the transmission fill tube nuts to the converter housing studs.

    Tighten:  Tighten the nuts to 18 N.m (13 lb ft).

    9. Fig 6: Removing Safety Chain From Around The Transmission (With 8.1L (L18) Engine)
    GM702527Courtesy of GENERAL MOTORS CORP.
  9. Remove the safety chain from around the transmission.
    10. Fig 7: Aligning Torque Converter Bolts (With 8.1L (L18) Engine)
    GM686680Courtesy of GENERAL MOTORS CORP.
  10. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts thru the starter opening. Have an assistant rotate the engine while aligning the bolts.
  11. If reusing the torque converter bolts, clean the bolt threads and apply Loctite 242 GM P/N 12345382 (Canadian P/N 10953489), or equivalent to the threads prior to installation.
  12. Install the torque converter bolts (3).

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

    13. Fig 8: Installing Converter Housing Inspection Cover (With 8.1L (L18) Engine)
    GM686693Courtesy of GENERAL MOTORS CORP.
  13. Install the converter housing inspection cover and bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    14. Fig 9: Installing Transmission Heat Shield (With 8.1L (L18) Engine)
    GM744180Courtesy of GENERAL MOTORS CORP.
  14. Install the transmission heat shield (1) and bolts (2).

    Tighten:  Tighten the bolts to 17 N.m (13 lb ft).

    15. Fig 10: Exhaust Hanger Bolts (With 8.1L (L18) Engine)
    GM694239Courtesy of GENERAL MOTORS CORP.
  15. Position the hanger and install the exhaust pipe hanger bolts.

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

    16. Fig 11: Installing Transmission Heat Shield And Bolt/Nut (With 8.1L (L18) Engine)
    GM744180Courtesy of GENERAL MOTORS CORP.
  16. Install the transmission heat shield (3) and bolt/nut (4, 5).

    Tighten:  Tighten the bolt/nut to 17 N.m (13 lb ft).

    17. Fig 12: Installing Fuel Line Retainer (With 8.1L (L18) Engine)
    GM702521Courtesy of GENERAL MOTORS CORP.
  17. Install the fuel line retainer (1) bolts to the left side of the transmission.

    Tighten:  Tighten the bolts to 2.5 N.m (22 lb in).

    18. Fig 13: Connecting PNP Switch Electrical Connector (With 8.1L (L18) Engine)
    GM702524Courtesy of GENERAL MOTORS CORP.
  18. Connect the PNP switch electrical connector.
  19. Disconnect the transmission main electrical connector (2).
    20. Fig 14: Connecting Output Speed Sensor Electrical Connector (With 8.1L (L18) Engine)
    GM702774Courtesy of GENERAL MOTORS CORP.
  20. Connect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and will be disconnected later.
  21. Connect the turbine speed sensor (1) and input speed sensor (2) electrical connectors.
    22. Fig 15: Installing Shift Cable Bracket And Bolts To The Transmission (With 8.1L (L18) Engine)
    GM686689Courtesy of GENERAL MOTORS CORP.
  22. Install the shift cable bracket (2) and bolts to the transmission.

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

    23. Fig 16: Connecting Shift Cable To The Selector Lever Ball Stud (With 8.1L (L18) Engine)
    GM686691Courtesy of GENERAL MOTORS CORP.
  23. Connect the shift cable to the selector lever ball stud (5) and install the cable to the bracket (3).
    24. Fig 17: Locating Transmission Mount Bolts
    GM702771Courtesy of GENERAL MOTORS CORP.
  24. Install the transmission mount.
  25. Install the transmission mount bolts (1).

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

  26. If the vehicle is equipped with 4WD, install the transfer case.
  27. If the vehicle is a 2WD, install the transmission support.
  28. If the vehicle is a 2WD, install the transmission support bolts and nuts.
    Fig 18: Identifying Crossmember & Bolts
    GM652595Courtesy of GENERAL MOTORS CORP.
  29. If the vehicle is a 2WD, install the transmission support bracket bolts.

    Tighten:  Tighten the bolts/nuts to 95 N.m (70 lb ft).

    30. Fig 19: Identifying Transmission Mount Nuts
    GM647997Courtesy of GENERAL MOTORS CORP.
  30. If the vehicle is a 2WD, install the transmission mount nuts.

    Tighten:  Tighten the nuts to 40 N.m (30 lb ft).

  31. Remove the transmission jack from the transmission.
  32. If the vehicle is a 2WD, remove the propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece in Propeller Shaft.
    33. Fig 20: Installing Starter Motor Bolts (With 8.1L (L18) Engine)
    GM747161Courtesy of GENERAL MOTORS CORP.
  33. Position the starter motor and install the starter motor bolts.

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

    34. Fig 21: Identifying Engine Shield And Retaining Bolts
    GM310119Courtesy of GENERAL MOTORS CORP.
  34. Install the engine protection shield and bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

  35. If the vehicle is equipped with a PTO unit, connect and/or install any necessary components.
    36. Fig 22: Installing Transmission Oil Cooler Lines (With 8.1L (L18) Engine)
    GM686709Courtesy of GENERAL MOTORS CORP.
  36. Remove the plugs from the transmission oil cooler line fittings in the transmission case.
  37. Flush the transmission oil cooler and lines, if necessary. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test .
  38. Connect the transmission oil cooler lines (1, 2) to the transmission.
  39. Lower the vehicle.
  40. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  41. Fill the transmission with new transmission fluid.
  42. Install the transmission fluid level indicator.
  43. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. Refer to FastLearn Procedure .
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