Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

Transmission Removal & Installation

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Zf S6-650 Transmissions



  1. Shift the transmission into 3rd or 4th speed gear.
  2.  
  3. Remove the shift lever.
  4.  
  5. Raise and suitably support the vehicle.
  6.  
  7. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft.
  8.  
  9. If equipped with 4 wheel drive (4WD), remove the transfer case.
  10.  
  11. Disconnect the clutch slave cylinder hydraulic hose quick connect at the master cylinder.
  12.  
  13. Disconnect the clutch slave cylinder line retaining clips.
  14.  
  15. If equipped with a 6.6L engine, disconnect the power take off, backup lamp and vehicle speed sensor connectors.
  16.  
  17. Remove the engine harness clips from the fuel feed/return brackets.
  18.  
  19. Remove the PTO connector from the fuel feed/return bracket.
  20.  
  21. Reposition the harness.
  22.  
  23. Remove the fuel lines from the fuel feed/return brackets.
  24.  
  25. If equipped with a 8.1L engine, disconnect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  26.  
  27. Remove the engine harness clips from the fuel feed/return brackets.
  28.  
  29. Remove the PTO connector from the fuel feed/return bracket.
  30.  
  31. Remove the oxygen sensors connectors from the fuel feed/return hose clip and transmission bracket.
  32.  
  33. Reposition the harness.
  34.  
  35. Remove the fuel lines from the fuel feed/return brackets.
  36.  
  37. If equipped with 4WD, remove the vent hose clip from the bracket.
  38.  
  39. Remove the vent hose clip nut and clip.
  40.  
  41. If equipped with 4WD, remove the vent hose clip from the fuel feed/return bracket.
  42.  
  43. Remove the starter.
  44.  
  45. Remove the exhaust pipe hanger bracket bolts and bracket.
  46.  
  47. Support the transmission with a suitable transmission jack.
  48.  
  49. Remove the transmission support
  50.  
  51. Remove the transmission bolts/studs.
  52.  
  53. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  54.  
  55. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  56.  
  57. Remove the insulator from the top of the transmission.
  58.  

To install:

  1. Install the insulator to the top of the transmission.
    NOTE
    Connect the clutch slave 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.  
  3. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  4.  
  5. Rotate the transmission clockwise onto the clutch hub splines.
  6.  
  7. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
  8.  
  9. Install the transmission studs and tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  12.  
  13. Install the transmission support.
  14.  
  15. Remove the transmission jack.
  16.  
  17. Install the exhaust pipe hanger bracket and bolts.
  18.  
  19. Install the starter.
  20.  
  21. If equipped with 4WD, install the vent hose clip to the fuel feed/return bracket.
  22.  
  23. Install the vent hose clip and nut.
  24.  
  25. Install the vent hose clip to the bracket.
  26.  
  27. Install the fuel lines to the fuel feed/return brackets.
  28.  
  29. Position the harness.
  30.  
  31. Install the oxygen sensors connectors to the fuel feed/return hose clip and transmission bracket.
  32.  
  33. Install the PTO connector to the fuel feed/return bracket.
  34.  
  35. Install the engine harness clips to the fuel feed/return brackets.
  36.  
  37. If equipped with a 8.1L engine, connect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  38.  
  39. Connect the clutch slave cylinder line retaining clips.
  40.  
  41. If equipped with 4WD, install the transfer case.
  42.  
  43. If equipped with a 6.6L engine, connect the power take off, backup lamp and vehicle speed sensor connectors.
  44.  
  45. If vehicle is a 2WD, install the rear propeller shaft.
  46.  
  47. Lower the vehicle.
  48.  
  49. Install the shift lever.
  50.  
  51. Fill the transmission with fluid.
  52.  
  53. Bleed the clutch hydraulic system, if necessary.
  54.  
  55. Connect the battery cables.
  56.  

 
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