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
     
    Shifter boot and lever
     
    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. Except the NV 3500, remove the top 2 transmission to housing bolts and insert 2 guide pins.
    NOTE
    The clutch housing on the NV 3500 is integral with the transmission as is the converter housing on the automatic transmissions.

  10.  
  11. On the NV 3500, remove the bolts securing the clutch housing to the engine.
    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. Be sure to support the clutch release bearing and support assembly during removal of the transmission.

  12.  
  13. 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.
  14.  
  15. 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
     

  16.  
  17. Carefully lower the transmission using the transmission jack.
  18.  

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 flywheel and replace the seal.
  4.  
  5. Inspect the flywheel ring gear teeth. If damaged, replace the flywheel.
  6.  
  7. Perform the following steps:
    1. Place the transmission in high gear. Lightly coat the input shaft splines with high temperature grease.
    2.  
    3. Raise the transmission into position.
    4.  
    5. On transmissions with a separate clutch housing, install the guide pins in the top 2 bolt holes if they have been removed.
    6.  
    7. Roll the transmission forward and engage the clutch splines. Keep pushing the transmission forward until it mates with the engine.
    8.  
    9. On transmissions with a separate clutch housing, remove the guide pins and install the bolts, tighten the bolts to 23 ft. lbs. (31 Nm).
    10.  
    11. On the NV 3500, install the transmission-to-engine bolts. Tighten the bolts to 35 ft. lbs. (47 Nm)
    12.  

  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. Install or connect the following:

    Wiring, clips, tubes and brackets etc
     
    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
     

  12.  
  13. Remove the transmission jack and engine support stands.

    Driveshaft
     
    Shifter lever and boot
     
    Negative battery cable
     

  14.  
  15. Refill the transmission with fluid.
  16.  
  17. Road test the vehicle and test for proper operation. Check for leaks.
  18.  

 
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