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Home >> GMC >> 2006 >> Sierra 1500 HD, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 22 (Manual Transmission - ZF S6-650 - Service, Troubleshooting & Diagnosis) >> Repair Instructions >> Transmission Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Install the insulator to the top of the transmission.
    2. NOTE: Connect the clutch actuator cylinder hose quick connect to the master cylinder before the transmission is fully installed. Failure to connect the hose could cause damage to the clutch pressure plate.
  2. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch actuator cylinder hydraulic hose quick connect to the 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.
    5. NOTE: Refer to Fastener Notice .
    Fig 1: Installing Transmission Studs
    GM776275Courtesy of GENERAL MOTORS CORP.
  5. If equipped with a 8.1L engine, install the transmission studs.

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

  6. Install the insulator to the top of the transmission.
    7. NOTE: Connect the clutch actuator cylinder hose quick connect to the master cylinder before the transmission is fully installed. Failure to connect the hose could cause damage to the clutch pressure plate.
  7. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch actuator cylinder hydraulic hose quick connect to the 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.
    Fig 2: Installing Transmission Bolts/Studs (6.6L Engine)
    GM776274Courtesy of GENERAL MOTORS CORP.

    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. Install the exhaust pipe hanger bracket and bolts.
    Fig 3: Exhaust Pipe Hanger Bracket
    GM694241Courtesy of GENERAL MOTORS CORP.

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

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

    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. 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:
    Fig 6: Reconnecting Electrical Connectors (8.1L Engine)
    GM776054Courtesy of GENERAL MOTORS CORP.
    • PTO (2), if connected
    • Oxygen sensors (1, 3)
    • Backup lamp switch (4)
    • VSS (5)
  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:
    Fig 7: Reconnecting Electrical Connectors (6.6L Engine)
    GM776052Courtesy of GENERAL MOTORS CORP.
    • PTO (2), if connected
    • Backup lamp switch (3)
    • VSS (4)
  29. Connect the clutch actuator cylinder line retaining clips.
    Fig 8: Connecting Clutch Actuator Cylinder Line
    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.
  30. 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).
  31. If vehicle is a 2WD, install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece in Propeller Shaft.
  32. Lower the vehicle.
  33. Install the shift lever. Refer to Shift Lever Assembly Replacement .
  34. Fill the transmission with fluid.
  35. Bleed the clutch hydraulic system, if necessary. Refer to Hydraulic Clutch Bleeding in Clutch.
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