Express, Savana, G1500, G2500, G3500, 1998-2005

Transmission Removal & Installation

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  1. Drain the transmission.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Shift cable, control lever and bracket
     
    Exhaust pipes
     
    Parking brake cables
     
    Driveshaft, matchmark for reassembly
     
    Transfer case, if equipped
     
    Transmission to engine braces (vehicles equipped with diesel engines have only 1 brace)
     
    Wiring harness at the transmission
     

  4.  
  5. Support the transmission with a transmission jack.

    Nut securing the transmission mount to the crossmember
     

  6.  
  7. Position a transmission jack or equivalent, under the transmission for support.
    NOTE
    Mark position of crossmember when removing to prevent incorrect installation. The tapered surface should face the rear.



    Crossmember. Visually inspect to see if other equipment, brackets or lines, must be removed to permit removal of transmission.
     

  8.  
  9. Perform the following:
    1. Remove the torque converter inspection cover.
    2.  
    3. Mark the alignment of the torque converter to the flexplate.
    4.  
    5. Remove the torque converter to flexplate bolts. Remove the dipstick tube and seal from the transmission. Plug the opening to avoid contamination.
    6.  
    7. Disconnect both transmission lines at the transmission and plug them to avoid contamination and leakage.
    8.  
    9. Position a J 21366 converter holding strap onto the transmission/torque converter to keep the torque converter from sliding off of the transmission turbine shaft.
      NOTE
      The use of guide pins will not only support the transmission but will prevent damage to the clutch disc. Guide pins can be made by using 2 bolts, the same as those just removed only longer, and cutting off the heads. Make an adjustment slot.

    10.  

  10.  
  11. Remove the remaining bolts and slide transmission straight back from engine. Use care to keep the transmission drive gear straight in line with clutch disc hub.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Ensure that the engine is supported with a jack stand before detaching the transmission from the engine.



    Wiring, clips, tubes and brackets etc., which would interfere with the removal of the transmission
     



    Transmission from the engine
     

  14.  
  15. Carefully lower the transmission using the transmission jack.
  16.  

To install:

  1. Check the area behind the torque converter for leaks. Replace the front seal, if required.
  2.  
  3. It is good practice to examine the area around the rear crankshaft seal, checking for leaks. If necessary, remove the flexplate and replace the seal.
  4.  
  5. Inspect the flexplate ring gear teeth. If damaged, replace the flexplate.
  6.  
  7. Perform the following steps:
    1. With tool J 21366 or equivalent, torque converter holding strap in place, raise the transmission into position with a transmission jack.
    2.  
    3. Remove the torque converter holding strap and slide the transmission into place. Slide the transmission straight onto the locating pins while lining up the marks on the flexplate and the torque converter. Be sure the transmission is fully seated against the rear of the engine block and the locating pins are completely engaged.
      WARNING
      DO NOT attempt to draw the transmission to the block with the mounting bolts. If the transmission is not properly seated, the bolts will break the transmission case.


      NOTE
      The torque converter must be flush with the flexplate and rotate freely by hand.

    4.  

  8.  
  9. When satisfied that the transmission is properly seated, install and tighten the transmission-to-engine bolts and/or studs to 34 ft. lbs. (47 Nm).
  10.  
  11. Perform the following steps:
    1. Install the dipstick tube and seal.
    2.  
    3. Check the alignment marks on the torque converter and flexplate to be sure that they are properly aligned. Install the torque converter bolts. Finger-tighten the bolts to ensure proper converter seating. When the converter is properly seated, tighten the bolts to 46 ft. lbs. (63 Nm).
    4.  
    5. Install the torque converter cover. Tighten the retaining bolts to 24 ft. lbs. (33 Nm) on the 4.3L engines or 89 inch lbs. (10 Nm) on the V8 engines.
    6.  

  12.  
  13. Install or connect the following:

    Wiring, clips, tubes and brackets etc
     
    Transmission cooling lines
     
    Shifter cable
     
    Starter
     
    Exhaust pipes
     
    Transmission crossmember. Torque the bolts to 56 ft. lbs. (77 Nm).
     
    Transmission mount on the transmission. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Nut and washer that secure the transmission mount to the crossmember. Torque the nut to 38 ft. lbs. (52 Nm).
     
    Transmission to engine brace(s) Torque the bolts to 41 ft. lbs. (55 Nm) for gasoline engines and to 51 ft. lbs. (70 Nm) for diesel engines.
     
    Transfer case, if equipped
     

  14.  
  15. Remove the transmission jack and engine support stands.

    Driveshaft
     
    Shifter lever and boot, on manual transmissions
     
    Negative battery cable
     

  16.  
  17. Refill the transmission with fluid.
  18.  
  19. Road test the vehicle and test for proper operation. Check for leaks.
  20.  

4L60E, 4L65E & 4L70E



  1. Remove or disconnect the following:
    NOTE
    Plug the oil level indicator tube opening in the transmission.



    Transmission fluid
     
    Transmission oil level indicator tube and seal from the transmission
     



    Shift cable end from the transmission shift lever ball stud
     
    Transfer case, if AWD
     
    Rear propeller shaft.
     

  2.  
  3. Plug the transmission oil cooler line connectors in the transmission case.
  4.  
  5. Remove or disconnect the following:

    Starter motor
     

  6.  
  7. Support the transmission with a transmission jack.
  8.  
  9. Remove or disconnect the following:

    Click image to see an enlarged view

    Fig. Exploded view of the trnasmission mounting-4L60E, 4L65E and 4L70E



    Torque converter access plug
     
    Mark the flywheel and the torque converter alignment
     
    Flywheel-to-torque converter bolts
     
    Transmission rear mount-to-transmission bolts and nut
     
    Heat shield-to-transmission bolts
     
    Transmission vent hose from the transmission
     
    Fuel lines from the transmission
     
    Wiring harness from the transmission
     
    Transmission-to-engine stud and bolt
     
    Studs and bolt securing the transmission to the engine.
     

  10.  
  11. Pull the transmission straight back.
  12.  
  13. The transmission from the vehicle
  14.  
  15. Flush the transmission oil cooler and cooling lines.
  16.  

To install:

  1. Support the transmission with a transmission jack.
  2.  
  3. Raise the transmission into place and remove the tool from the transmission.
  4.  
  5. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
  6.  
  7. Install or connect the following:

    Studs and bolt securing the transmission to the engine. Tighten to 34 ft. lbs. (47 Nm).
     
    Flywheel to torque converter bolts. Tighten to 46 ft. lbs. (63 Nm) and use Loctite 242 on the threads
     
    Torque converter access plug
     
    Transmission vent hose to the transmission
     
    Fuel lines to the transmission
     
    Wiring harness to the transmission.
     
    Heat shield-to-transmission bolts and tighten to 13 ft. lbs. (17 Nm)
     
    Transmission rear mount-to-transmission bolt and nut and tighten to 18 ft. lbs. (25 Nm)
     

  8.  
  9. Remove the transmission jack from the transmission.
  10.  
  11. Unplug the transmission oil cooler line connectors in the transmission case.
  12.  
  13. Install or connect the following:

    Transmission oil cooler lines
     
    Transfer case, if equipped
     
    Rear propeller shaft
     
    Shift cable end to the transmission shift lever ball stud
     

  14.  
  15. Unplug the oil level indicator tube opening in the transmission.
  16.  
  17. Install the transmission oil level indicator tube and seal to the transmission.
  18.  
  19. Tighten the oil pan bolts and fill the transmission with transmission fluid.
  20.  
  21. Lower the vehicle.
  22.  

4L80E & 4L85E



  1. Remove or disconnect the following:

    Transmission fluid
     
    Transmission oil level indicator tube and seal from the transmission
     

  2.  
  3. Plug the oil level indicator tube opening in the transmission.

    Shift cable from the transmission shift lever ball stud
     
    Transfer case, if AWD
     
    Rear propeller shaft.
     
    Transmission oil cooler lines, then plug thee openings in the transmission case
     
    Starter motor
     

  4.  
  5. Support the transmission with a transmission jack.

    Heat shield
     
    Transmission vent hose
     
    Fuel lines from the transmission
     
    Wiring harness from the transmission
     
    Transmission brace-to-engine bracket and transmission nut and bolt
     
    Torque converter cover
     
    Mark the flywheel and the torque converter alignment
     
    Flywheel to torque converter bolts
     
    Transmission rear mount
     
    Stud and bolt on the right side securing the transmission to the engine
     
    Remaining six studs and the bolt securing the transmission to the engine

    Click image to see an enlarged view

    Fig. Exploded view of the trnasmission mounting-4L80E and 4L85E

     

  6.  
  7. Pull the transmission straight back. Remove the transmission from the vehicle.
  8.  
  9. Flush the transmission oil cooler and cooling lines when you remove the transmission.
  10.  

To install:

  1. Support the transmission with a transmission jack.
  2.  
  3. Raise the transmission into place and remove the tool from the transmission.
  4.  
  5. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
  6.  
  7. Install or connect the following:

    Six studs and bolt securing the transmission to the engine. Tighten to 34 ft. lbs. (47 Nm).
     
    Stud and bolt on the right side securing the transmission to the engine. Tighten to 34 ft. lbs. (47 Nm).
     
    Flywheel-to-torque converter bolts and tighten to 46 ft. lbs. (63 Nm).
     
    Transmission vent hose
     
    Fuel lines
     
    Wiring harness
     
    Heat shield. Tighten the bolts to 13 ft. lbs. (17 Nm).
     
    Transmission rear mount-to-transmission nuts and bolt. Tighten to 18 ft. lbs. (25 Nm).
     
    Transmission brace. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
     

  8.  
  9. Remove the transmission jack from the transmission.

    Starter motor
     

  10.  
  11. Unplug the transmission oil cooler line connectors in the transmission case.
  12.  
  13. Connect the transmission oil cooler lines to the transmission.
  14.  
  15. Install or connect the following:

    Rear propeller shaft
     
    Transfer case, if AWD
     
    Shift cable end to the transmission shift lever ball stud
     

  16.  
  17. Unplug the oil level indicator tube opening in the transmission.
  18.  
  19. Install the transmission oil level indicator tube and seal to the transmission.
  20.  
  21. Tighten the oil pan bolts and fill the transmission with transmission fluid.
  22.  
  23. Lower the vehicle.
  24.  

 
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