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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 993 (Engine Mechanical - 4.8L, 5.3L & 6.0L (Repair Instructions - 1 Of 3)) >> Repair Instructions (On-Vehicle & Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions >> Oil Pan Replacement >> 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.
  1. If equipped with regular production option (RPO) HP2, it is necessary to drain the cooling system and engine block. Refer to Draining and Filling Cooling System (with HP2) or Draining and Filling Cooling System (without HP2) in Engine Cooling.
  2. If equipped with four wheel drive (4WD), remove the inner axle housing nuts and washers from the bracket.
    3. Fig 1: View Of Inner Axle Housing Nuts
    GM834241Courtesy of GENERAL MOTORS CORP.
  3. Support the front drive axle with a suitable jack.
  4. If equipped with 4WD, remove the differential carrier lower mounting bolt and nut.
    5. Fig 2: View Of Differential Carrier Lower Mounting Bolt
    GM834278Courtesy of GENERAL MOTORS CORP.
  5. If equipped with 4WD, remove the differential carrier upper mounting bolt and nut.
    6. Fig 3: View Of Differential Carrier Upper Mounting Bolt
    GM834276Courtesy of GENERAL MOTORS CORP.
  6. Lower the front drive axle.
  7. Remove the transmission cover bolt.
    8. Fig 4: View Of Transmission Cover Bolt
    GM663487Courtesy of GENERAL MOTORS CORP.
  8. If equipped, remove the oil pan skid plate bolts.
  9. Remove the oil pan skid plate.
    10. Fig 5: Identifying Oil Pan Skid Plate
    GM309158Courtesy of GENERAL MOTORS CORP.
  10. Remove the crossbar bolts.
  11. Remove the crossbar.
    12. Fig 6: View Of Crossbar Bolts & Bar (2WD)
    GM328107Courtesy of GENERAL MOTORS CORP.
  12. Remove the transmission cover bolt and cover.
    13. Fig 7: View Of Transmission Cover & Bolt
    GM832978Courtesy of GENERAL MOTORS CORP.
  13. Drain the engine oil and remove the engine oil filter.
  14. Re-install the drain plug and oil filter until snug.
  15. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.
    16. Fig 8: Identifying Stud & Bolt Securing Transmission To Engine (Right Side)
    GM394448Courtesy of GENERAL MOTORS CORP.
  16. Remove the bottom bolt on the left side.
    17. Fig 9: Identifying Six Studs & One Bolt Securing Transmission To Engine
    GM394446Courtesy of GENERAL MOTORS CORP.
  17. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.
    18. Fig 10: View Of Transmission Converter Cover Bolt (4L80-E)
    GM396795Courtesy of GENERAL MOTORS CORP.
  18. If equipped with a manual transmission, remove the two bottom bellhousing bolts.
    19. Fig 11: View Of Transmission Mounting Bolts (Manual Transmission)
    GM394442Courtesy of GENERAL MOTORS CORP.
  19. Disconnect the oil level sensor electrical connector (3).
    20. Fig 12: View Of Oil Level Sensor & CKP Sensor Electrical Connector
    GM1235682Courtesy of GENERAL MOTORS CORP.
  20. Remove the battery cable channel bolt.
    21. Fig 13: View Of Battery Cable Channel Bolt
    GM1236368Courtesy of GENERAL MOTORS CORP.
  21. Slide the channel pin out of the oil pan tab.
  22. Remove the following from the positive battery cable clip:
    • Engine wiring harness clip
    • Positive battery cable clip
    23. Fig 14: View Of Engine Wiring Harness Clip & Positive Battery Cable Clip
    GM1236367Courtesy of GENERAL MOTORS CORP.
  23. Remove the engine oil cooler lines from the positive battery cable clip.
  24. Remove the positive battery cable clip bolt and clip.
    25. Fig 15: View Of Positive Battery Cable Clip & Bolt
    GM310672Courtesy of GENERAL MOTORS CORP.
  25. Remove the oil pan bolts.
  26. Remove the oil pan.
    27. Fig 16: View Of Oil Pan & Bolts
    GM683355Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required.
  27. Drill (3) out the oil pan gasket retaining rivets (2), if required.
  28. Remove the gasket (1) from the pan.
    29. Fig 17: Drilling Oil Pan Gasket Retaining Rivets
    GM384699Courtesy of GENERAL MOTORS CORP.
  29. Discard the gasket and rivets.
  30. If required, clean and inspect the engine oil pan. Refer to Oil Pan Cleaning and Inspection .
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