S10 Pickup, Sonoma 2000-2004

Transmission Removal & Installation

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  1. Shift the transmission into 3rd or 4th gear position.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Shift lever and the if necessary, the shift housing
     
    Parking brake cable for clearance
     
    Propeller shaft
     
    Side plate, if equipped
     
    Transfer case and shift lever, on 4WD models
     
    All wiring harness that would interfere with transmission removal
     
    Fuel line retainers from the rear crossmember
     
    Muffler from the catalytic converter
     
    Exhaust pipes from the exhaust manifold
     
    Catalytic converter hangar, if necessary
     
    Exhaust section
     
    Bolts and nuts attaching any transmission braces to the engine and transmission
     

  4.  
  5. Disconnect 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.  

  6.  
  7. Remove or disconnect the following:

    Bolts securing the clutch housing cover to the transmission, if equipped
     
    Clutch plate and clutch cover, if necessary
     

  8.  
  9. Support the transmission with a suitable jack.

    Rear crossmember from the frame rail
     
    Wiring harness from the front crossmember, if equipped. Move the wiring harness away from the transmission oil pan. Lower the transmission enough to gain access to the top of the transmission.
     
    Fuel line retainers or wiring harnesses from the top of the transmission
     
    Bolt, washer, and nut securing the wiring harness ground wires to the engine block
     
    Bolts retaining the transmission to the engine. Pull the transmission straight back on the clutch hub splines.
     

  10.  
  11. Lower the transmission using the transmission jack.
  12.  

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.
    NOTE
    On some models, it may be necessary to rotate the transmission clockwise while inserting it into the clutch hub.

  4.  
  5. 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.
  6.  
  7. Tighten the transmission mounting bolts to 35 ft. lbs. (47 Nm).
  8.  
  9. Do not remove the transmission jack until the crossmembers have been installed.
  10.  
  11. Check the transmission fluid level and replenish as necessary.
  12.  

 
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