Astro, Safari 1997-2005

Transmission Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle.
  4.  
  5. Drain the transmission fluid.
  6.  
  7. Remove the rear propeller shaft.
  8.  
  9. Support the transmission with a transmission jack.
  10.  
  11. Remove the nut (2WD) or nuts (AWD) securing the transmission mount to the transmission support.
  12.  
  13. Raise the transmission slightly and remove the transmission support from the vehicle.
  14.  
  15. Remove front exhaust pipe assembly.
  16.  
  17. Remove starter motor.
  18.  
  19. Lower the transmission to gain access to the top and sides of the transmission.
  20.  
  21. Remove vent tube hose and the electrical connections from the transfer case, if equipped.
  22.  
  23. Remove transmission mount.
  24.  
  25. Remove transfer case, if equipped.
  26.  
  27. Disconnect range selector cable end from the transmission range selector lever ball stud and bracket.
  28.  
  29. Remove transmission heat shield.
  30.  
  31. Remove transmission vent hose.
  32.  
  33. Disconnect Park/Neutral Position (PNP) switch connector.
  34.  
  35. Remove main electrical connector from the transmission.
  36.  
  37. Remove bolt that secures the fuel line bracket to the left side of the transmission.
  38.  
  39. Remove torque converter access plug.
  40.  
  41. Remove flywheel-to-torque converter bolts.
  42.  
  43. Disconnect transmission oil cooler pipes from the transmission, then plug the openings in the transmission case.
  44.  
  45. Remove stud and the bolt securing the transmission to the engine.
  46.  
  47. Remove six studs and one bolt securing the transmission to the engine.
  48.  
  49. Install tool J 21366 converter holding strap onto the transmission bell housing to retain the torque converter.
  50.  
  51. Pull the transmission straight back.
  52.  
  53. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.

    Click image to see an enlarged view

    Fig. Exploded view of the automatic transmission-2002 vehicle shown

  54.  

To install:

  1. Install the converter holding strap onto the transmission bell housing to retain the torque converter.
  2.  
  3. Support the transmission with a transmission jack.
  4.  
  5. Raise the transmission into place while simultaneously installing the fluid indicator tube.
  6.  
  7. Remove the converter holding strap from the transmission.
  8.  
  9. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand.
  10.  
  11. Install the fasteners securing the transmission to the engine. Tighten the studs and the bolt to 35 ft. lbs. (47 Nm).
  12.  
  13. Install flywheel-to-torque converter bolts and tighten to 46 ft. lbs. (63 Nm).
  14.  
  15. Install torque converter access plug.
  16.  
  17. Install transmission vent hose, fuel lines, and the wiring harness.
  18.  
  19. Install heat shield.
  20.  
  21. Connect range selector cable.
  22.  
  23. Install transfer case, if equipped.
  24.  
  25. Install transmission mount to the transmission (2WD) or the transfer case adapter (AWD).
  26.  
  27. Connect vent hose and electrical connectors to the transfer case, if equipped.
  28.  
  29. Install starter motor.
  30.  
  31. Install front exhaust pipe assembly.
  32.  
  33. Install transmission support.
  34.  
  35. Install transmission mount to transmission support nut (2WD) or nuts (AWD). Tighten the nut(s) to 29 ft. lbs. (40 Nm).
  36.  
  37. Remove the transmission jack.
  38.  
  39. Install rear propeller shaft.
    NOTE
    Flush the transmission oil cooler and oil cooler pipes at this time, if necessary.

  40.  
  41. Connect oil cooler pipes to the transmission.
  42.  
  43. Lower the vehicle.
  44.  
  45. Connect the negative battery cable.
  46.  
  47. Fill the transmission to the proper level.
  48.  
  49. Test the vehicle for proper operation and check for leaks.
  50.  

 
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