GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Transmission

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REMOVAL & INSTALLATION



On many of the vehicles covered by this information, the upper transmission-to-engine bolts (especially the upper left) may be difficult to access and withdraw due to the close proximity of the cowl sheet metal. Even if a wrench fits over the bolt, there may be insufficient room to fully unthread it. The factory recommended procedure to access these bolts is to remove the left body mount bolt(s) from under the cab and loosen the radiator support mounting, then carefully jack the body up off the frame until sufficient clearance exists. Place wooden blocks between the body and frame to support the body (this is to prevent damage and for SAFETY) during service. In some cases, this may be unnecessary if the engine will pivot downward sufficiently on the motor mount to allow bolt access or if the motor mounts are removed and the engine is supported using a lifting device. BUT DO NOT try this if it appears that the mounts will be damaged by the stress. Also, be sure the engine is properly supported at ALL times and that no components will be damaged. Watch that the distributor does not contact the cowl and that the cooling fan remains clear of the radiator and shroud assembly. When in doubt, unbolt and raise the body for access.

1994-95 Vehicles

See Figure 1



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Fig. Fig. 1: Transmission mounting and components-1994 4L60-E shown

  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely using jackstands.
  4.  
  5. Drain the transmission fluid. For details, please refer to the pan procedure located in Routine Maintenance of this repair guide.
  6.  
  7. On 1994 vehicles, disconnect the shift linkage from the transmission.
  8.  
  9. On 1995 vehicles, disconnect the shift cable from the transmission.
  10.  
  11. Matchmark and remove the rear driveshaft.
  12.  
  13. For 4WD vehicles, remove the transfer case assembly. For details, please refer to the procedure located later in this section.
  14.  
  15. Disconnect the fuel lines.
  16.  
  17. Remove the transmission crossmember-to-frame retaining bolts and member-to-transmission retainer(s), then remove the crossmember from the vehicle. Take care not to stretch or damage any cables or wiring when attempting to remove the crossmember.
  18.  
  19. Disconnect the exhaust pipe(s) from the manifold(s).
  20.  
  21. Remove the flywheel inspection cover and matchmark the flywheel-to-torque converter relationship, then remove the flywheel-to-torque converter bolts.
  22.  
  23. Remove the fuel lines and wiring harness from the transmission.
  24.  
  25. Make sure the transmission is properly supported by a floor jack, then remove the transmission-to-engine bolts. Note the positioning of any brackets, clips or harnesses as they are removed.
  26.  
  27. Remove the dipstick tube and seal, then plug or cover the opening in the transmission housing in order to prevent system contamination.
  28.  
  29. Disconnect the cooler lines. Plug or cover all openings in order to prevent system contamination or excessive fluid spillage.
  30.  
  31. Support the engine using a jackstand and a block of wood.
  32.  
  33. On 4WD vehicles, remove the transfer case shifter and set it aside.
  34.  
  35. Using the floor jack to support the transmission, pull it straight back and disengage it from the engine. Carefully lower the transmission and remove it from the vehicle. If possible, install a torque converter retaining strap before attempting to lower the transmission. This will prevent the converter from possibly falling and causing damage and/or personal injury.
  36.  

To install:

Installation is the reverse of removal, but please note the following inportant steps>

  1. Make sure the torque converter is properly seated and a retaining strap is installed.
  2.  
  3. Using the floor jack, carefully raise the transmission into position in the vehicle, then remove the converter retaining strap. Slide the transmission straight onto the locating pins while aligning the marks on the flywheel and torque converter.
  4.  

The converter must be flush on the flywheel and rotate freely by hand.

  1. Install the transmission-to-engine retainers, taking care to properly reposition all brackets, clips and harness, as noted during removal. Do NOT install the dipstick tube or transmission support brace screws at this time.
  2.  
  3. Tighten the transmission-to-engine retainers to 23 ft. lbs. (32 Nm).
  4.  
  5. Tighten the flywheel-to-converter bolts 46 ft. lbs. (63 Nm).
  6.  
  7. Tighten the transmission crossmember-to-frame bolts to 56 ft. lbs. (77 Nm).
  8.  
  9. Refill the transmission with the proper amount and type of fluid.
  10.  
  11. Connect the negative battery cable. Start the vehicle and allow to warm while checking for leaks. Road test the vehicle to check for shift quality.
  12.  

1996-99 Vehicles

See Figures 2 and 3



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Fig. Fig. 2: Transmission mounting on 1996-99 2.2L engines



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Fig. Fig. 3: Transmission mounting on 1996-99 4.3L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely using jackstands.
  4.  
  5. Drain the transmission fluid.
  6.  
  7. Remove the driveshaft from the transmission (2WD) and transfer case, if equipped (4WD).
  8.  
  9. Support the transmission with a suitable transmission jack.
  10.  
  11. Remove the shift cable from the transmission control lever and bracket.
  12.  
  13. Remove the nut and washer securing the transmission mount to the crossmember.
  14.  
  15. Remove the bolts and washers securing the mount to the transmission.
  16.  
  17. Disconnect the exhaust pipe from the exhaust manifold(s).
  18.  
  19. If equipped, remove the bolts securing the converter pan cover to the transmission.
  20.  
  21. Remove the 3 bolts securing the torque converter to the flywheel.
  22.  
  23. Remove the bolt, clip, and strap securing the three fuel lines and transmission vent hose to the transmission case.
  24.  
  25. Remove the bolts and nut securing the transmission to the engine.
  26.  
  27. Remove the oil filler tube and seal from the transmission.
  28.  
  29. Disconnect the transmission cooler lines from the transmission. Plug the lines and the ports in the transmission.
  30.  
  31. Unplug the wiring harness connectors from the transmission.
  32.  
  33. Inspect for any other wiring, brackets etc. which may interfere with the removal of the transmission.
  34.  
  35. Since the transmission acts as a rear engine mount, properly support the rear of the engine with an underbody support of other suitable support before attempting to remove the transmission. Otherwise the rear of the engine may pitch downward and components on the rear of the engine and on the firewall may be damaged.
  36.  
  37. Remove the transmission from the engine by pulling the transmission rearward to disengage it from the locator dowel pins on the back of the block. Carefully lower the transmission from the vehicle. Use care that the torque converter does not fall out of the front of the transmission.
  38.  

Use converter holding strap tool No. J-21366, or equivalent, to secure the torque converter to the transmission during removal and installation procedures.

To install:

Installation is the reverse of removal, but please note the following important steps.

  1. Make sure the torque converter is fully seated in the pump drive. If not, the transmission will not fit tightly to the rear of the engine block.
  2.  
  3. Raise the transmission into position and remove the torque converter holding strap and carefully. Slide the transmission forward until the dowel pins are engaged.
  4.  
  5. The torque converter should be flush with the flywheel and turn freely by hand.
  6.  
  7. Install the transmission-to-engine bolts. Tighten the bolts to 66 ft. lbs. (90 Nm) on 1996 2.2L models and 34 ft. lbs. (47 Nm) on 1996-99 4.3L vehicles and 1997-99 2.2L vehicles.
  8.  
  9. Tighten the torque converter-to-flywheel bolts to 46 ft. lbs. (63 Nm).
  10.  
  11. If equipped, tighten the converter pan cover to the transmission bolts to 37 ft. lbs. (50 Nm)
  12.  
  13. Tighten the bolts and washers securing the transmission mount to 35 ft. lbs. (47 Nm).
  14.  
  15. Tighten the nut and washer securing the transmission mount to the crossmember to 38 ft. lbs. (52 Nm).
  16.  
  17. Refill the transmission with the proper amount and type of fluid.
  18.  
  19. Connect the negative battery cable. Start the vehicle and allow to warm while checking for leaks. Road test the vehicle to check for shift quality.
  20.  

 
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