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

Transmission

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REMOVAL & INSTALLATION



See Figures 1 through 48



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Fig. Fig. 1: Once the driveshaft has been disconnected at the rear differential, slide the shaft from the transmission -NVG 3500 transmission tailshaft



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Fig. Fig. 2: Catalytic converter hanger assembly under the transmission-common application



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Fig. Fig. 3: Common brace mounting-left side of the 2.2L gasoline engine shown



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Fig. Fig. 4: Common transmission-to-engine mounting-New Venture Gear 3500 model shown



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Fig. Fig. 5: Move the starter motor back out of the way so that inspection over can be removed-NVG 3500 transmission



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Fig. Fig. 6: Remove the inspection plate-NVG 3500 transmission



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Fig. Fig. 7: With the transmission supported securely with a jack, remove the crossmember-to-frame bolts-NVG 3500 transmission



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Fig. Fig. 8: With the transmission supported securely with a jack, remove the mount-to-frame bolts-NVG 3500 transmission



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Fig. Fig. 9: With the transmission supported securely with a jack, the crossmember can be safely removed -NVG 3500 transmission



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Fig. Fig. 10: Remove the remaining section of the exhaust system-NVG 3500 transmission



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Fig. Fig. 11: Loosen and remove the bell housing bolts-NVG 3500 transmission



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Fig. Fig. 12: Carefully pull the transmission away from the engine to clear the input shaft and lower it down-NVG 3500 transmission

  1. On Borg Warner and 1994-95 NVG 3500 models, shift the transmission into neutral.
  2.  
  3. On NVG 1500 and 1996-99 NVG models, shift the transmission into 3rd or 4th gear position.
  4.  
  5. Disconnect the negative battery cable.
  6.  


WARNING
Refer to the Shift Lever removal and installation procedures before attempting to remove the shift lever housing.

  1. Remove the shift lever and the if necessary, the shift housing.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Remove the parking brake cable for clearance.
  6.  
  7. Remove the propeller shaft.
  8.  
  9. If equipped, remove the skid plate.
  10.  
  11. On 4WD vehicles, remove the transfer case and shift lever. For details, please refer to the procedure later in this section.
  12.  
  13. Tag and disconnect all wiring harness that would interfere with transmission removal.
  14.  
  15. For 1994-95 4.3L engines properly relieve the fuel system pressure, then disconnect the fuel lines at the engine.
  16.  
  17. For 1994-95 2.2L engines, disconnect the fuel lines from the top cover.
  18.  
  19. For 1996-99 vehicles, disconnect the fuel line retainers from the rear crossmember.
  20.  
  21. Detach the muffler from the catalytic converter.
  22.  
  23. Disconnect the exhaust pipes from the exhaust manifold.
  24.  
  25. If necessary, remove the catalytic converter hanger.
  26.  
  27. Remove the exhaust section.
  28.  
  29. Remove the bolts and nuts attaching any transmission braces to the engine and transmission.
  30.  
  31. On models equipped with the NVG transmission, detach the hydraulic clutch quick-connect from the concentric slave cylinder following 1 of the 2 steps:
    1. Use 2 small prytools at 180 degrees from each other to depress the white plastic sleeve on the quick connect to separate the clutch line from the concentric slave cylinder quick connect.
    2.  
    3. Use special tool J-36221 to depress the white plastic sleeve on the quick connect to separate the clutch line end from the concentric slave cylinder quick connect.
    4.  

  32.  
  33. On models equipped with the Borg Warner transmission, remove the slave cylinder from the transmission. If the cylinder can be repositioned with the hydraulics intact, simply support it out of the way, but make sure the line is not stretched, kinked or otherwise damaged. If necessary, disconnect the line and remove the cylinder completely.
  34.  
  35. If equipped, remove the bolts securing the clutch housing cover to the transmission.
  36.  
  37. If necessary, remove the clutch plate and clutch cover.
  38.  
  39. Support the transmission with a suitable jack.
  40.  
  41. Remove the rear crossmember from the frame rail.
  42.  
  43. If equipped, detach the wiring harness from the front crossmember. Move the wiring harness away from the transmission oil pan. Lower the transmission enough to gain access to the top of the transmission.
  44.  
  45. Remove the fuel line retainers or wiring harness's from the top of the transmission.
  46.  
  47. If necessary, remove the bolt, washer, and nut securing the wiring harness ground wires to the engine block.
  48.  
  49. Unfasten the bolts retaining the transmission to the engine. Pull the transmission straight back on the clutch hub splines.
  50.  
  51. Lower the transmission using the transmission jack.
  52.  

To install:

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

  1. Place a THIN coat of high-temperature grease on the main drive gear (input shaft) splines.
  2.  
  3. Secure the transmission to the floor jack and raise the transmission into position.
  4.  

On some models that use the NVG 3500 transmission, it may be necessary to rotate the transmission clockwise while inserting it into the clutch hub.

  1. Slowly insert the input shaft through the clutch. Rotate the output shaft slowly to engage the splines of the input shaft into the clutch while pushing the transmission forward into place. Do not force the transmission into position, the transmission should easily fall into place once everything is properly aligned.
  2.  
  3. Tighten the transmission mounting bolts as follows:

    Borg Warner transmission: 55 ft. lbs. (75 Nm)
     
    NVG transmissions: 35 ft. lbs. (47 Nm)
     

  4.  
  5. Do not remove the transmission jack until the crossmembers have been installed.
  6.  
  7. Check the transmission fluid level and replenish as necessary.
  8.  



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Fig. Fig. 13: Remove the insulator from the case using a suitable pry tool to access the shift housing retainers-NVG 1500 transmission



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Fig. Fig. 14: Unfasten the shift housing retainers-NVG 1500 transmission



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Fig. Fig. 15: Remove the shift housing assembly. Do not disassemble any of its components-NVG 1500 transmission



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Fig. Fig. 16: Place a clean rag or paper towels in the transmission shift housing cavity to prevent dirt from entering the transmission-NVG 1500 transmission



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Fig. Fig. 17: Unfasten the bolts that attach the driveshaft retainers to the pinion flange ...



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Fig. Fig. 18: ... and remove the retainers-NVG 1500 transmission



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Fig. Fig. 19: Separate the yoke and cross assembly from the pinion flange by sliding the driveshaft forward-NVG 1500 transmission



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Fig. Fig. 20: Lower the rear end of the driveshaft and slide the shaft out of the transmission-NVG 1500 transmission



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Fig. Fig. 21: Install a plug in the transmission to avoid both fluid leaking out and dirt from getting in-NVG 1500 transmission



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Fig. Fig. 22: Unfasten any wiring harness clip retainers attached to the transmission-NVG 1500 transmission



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Fig. Fig. 23: If equipped, unplug the downstream oxygen sensor electrical connection and unfasten the sensor harness retaining clip (arrow) from the crossmember-NVG 1500 transmission



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Fig. Fig. 24: Unfasten the nuts that attach the muffler to the catalytic converter-NVG 1500 transmission



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Fig. Fig. 25: Using a long extension, unfasten the exhaust pipe-to-manifold retaining bolts-NVG 1500 transmission



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Fig. Fig. 26: Unfasten the catalytic converter hanger retaining bolts ...



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Fig. Fig. 27: ... and remove the catalytic converter and exhaust pipe-NVG 1500 transmission



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Fig. Fig. 28: Unplug the electrical connections from the speed sensor (1) and the back-up switch (2) -NVG 1500 transmission



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Fig. Fig. 29: Unfasten any fuel line retaining clips from the side of the transmission ...



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Fig. Fig. 30: ... and any clip retainer that attaches the fuel lines to the crossmember-NVG 1500 transmission



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Fig. Fig. 31: Unfasten the bolts that attach the braces to the transmission-NVG 1500 transmission



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Fig. Fig. 32: The concentric slave cylinder fitting may be disconnected using two screw drivers at 180 degrees apart to depress the white plastic sleeve on the fitting-NVG 1500 transmission



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Fig. Fig. 33: After the sleeve is disengaged, separate the fitting from the slave cylinder-NVG 1500 transmission



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Fig. Fig. 34: Location of the clutch cover bolts on the drivers side-NVG 1500 transmission



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Fig. Fig. 35: Location of the clutch cover bolts on the passenger side-NVG 1500 transmission



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Fig. Fig. 36: After unfastening the cover bolts, remove both pieces of the cover-NVG 1500 transmission



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Fig. Fig. 37: Location of the lower transmission mounting bolt (passenger side).This bolt also retains a ground strap and has a nut on the other side. A back-up wrench will be needed to loosen this bolt-NVG 1500 transmission



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Fig. Fig. 38: The lower transmission bolt on the passenger side is located in front of the starter motor casting on the transmission-NVG 1500 transmission



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Fig. Fig. 39: Location of one of the transmission upper mounting bolts (passenger side). The top bolts are accessible using a long extension with a swivel socket and lowering the rear of the transmission-NVG 1500 transmission



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Fig. Fig. 40: The passenger side of the transmission crossmember is retained by four nuts and bolts. A back-wrench is required to unfasten these bolts-NVG 1500 transmission



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Fig. Fig. 41: The drivers side of the transmission crossmember is retained by a series of nuts and bolts. A back-up wrench is needed to unfasten the bolts indicated by the arrows-NVG 1500 transmission



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Fig. Fig. 42: The transmission rear mount is retained by a nut-NVG 1500 transmission



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Fig. Fig. 43: Before removing the crossmember, support the transmission with a suitable jack-NVG 1500 transmission



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Fig. Fig. 44: Unfasten the transmission mount-to-crossmember retaining nut-NVG 1500 transmission



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Fig. Fig. 45: Using a back-up wrench unfasten the crossmember retaining bolts on the drivers side-NVG 1500 transmission



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Fig. Fig. 46: Unfastening the passenger side crossmember retaining bolts using a back-up wrench-NVG 1500 transmission



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Fig. Fig. 47: After all the crossmember retainers have been unfastened, remove the crossmember from the vehicle-NVG 1500 transmission



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Fig. Fig. 48: After all the transmission-to-engine bolts have been unfastened, slide the transmission backwards until the shaft is clear of the clutch assembly-NVG 1500 transmission

 
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