Sierra, Silverado 2006-2007

Transmission Removal & Installation

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Nv3500



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

    Shift lever
     
    Shift tower
     
    Transmission oil
     
    If equipped with a transfer case, remove the front propeller shaft
     
    Rear propeller shaft.
     

  4.  
  5. If equipped with a transfer case, remove or disconnect the following:

    Two transfer case shields
     
    Manual transfer case shift linkage

    Click image to see an enlarged view

    Fig. NV3500 removal

     
    Bolt securing the left side support brace to the transmission
     
    Bolt and stud securing the left side support brace to the transfer case
     
    Bolt securing the right side support brace to the transmission
     
    Bolt securing the right side support brace to the transfer case
     

  6.  
  7. Using tool J42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.
  8.  
  9. Disconnect the wiring harness and connectors from the vehicle speed sensor, backup lamp switch, and transmission harness retainers.
  10.  
  11. If equipped with a 4.3L engine, remove the two bolts securing the clutch housing cover. Remove the transmission rear mount. Support the transmission with a transmission jack.
  12.  
  13. Remove or disconnect the following:

    Bolts securing the bottom right side of the transmission to the engine
     
    Stud securing the right side of the transmission to the engine
     
    Bolt and six studs securing the transmission to the engine
     

  14.  
  15. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover.

    Transmission from the vehicle
     
    Clutch plate and the clutch cover from the engine flywheel, if required
     

  16.  

To install:

  1. Install the clutch plate and the clutch cover to the engine flywheel if removed.
  2.  
  3. Ensure the transmission is positioned in the 3rd or 4th speed gear. Rotate the transmission clockwise onto the clutch hub splines. Install the bolt and the studs securing the transmission to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Install or connect the following:

    Stud securing the right side of the transmission to the engine and tighten to 37 ft. lbs. (50 Nm)
     
    Bolts securing the bottom right side of the transmission to the engine and tighten to 37 ft. lbs. (50 Nm)
     
    Clutch housing cover using the two bolts (4.3L engine). Tighten the bolts to 10 ft. lbs. (14 Nm).
     
    Transmission rear mount
     
    Clutch line to the concentric slave cylinder
     

  6.  
  7. If equipped with a transfer case, install or connect the following:

    Right side support brace-to-transmission bolt and tighten to 37 ft. lbs. (50 Nm)
     
    Right side support brace-to-transfer case bolts and tighten to 37 ft. lbs. (50 Nm)
     
    Left side support brace-to-transfer case bolt(s) and stud and tighten to 37 ft. lbs. (50 Nm)
     
    Left side support brace-to-transmission bolts and tighten to 37 ft. lbs. (50 Nm)
     
    Manual transfer case shift linkage.
     
    Two transfer case shields
     
    Front propeller shaft
     

  8.  
  9. Install or connect the following:

    The rear propeller shaft.
     
    The shift tower.
     
    Transmission with transmission fluid
     
    Shift lever
     

  10.  

Nv4500



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

    The shift lever
     
    The shift tower
     
    The transmission oil
     
    Front propeller shaft, 4WD only
     
    Rear propeller shaft
     
    Two transfer case shields
     
    Manual transfer case shift linkage, if equipped
     
    Two bolts securing the right side support bracket to the transmission
     

  4.  
  5. Using tool J42371, push back on the white plastic sleeve on the quick connect in order to separate the hydraulic clutch line from the concentric slave cylinder quick connect.

    Click image to see an enlarged view

    Fig. NV4500 removal



    Vehicle Speed Sensor (VSS) connector and harness
     
    Backup lamp switch connector and harness
     
    Transmission harness retainers
     
    Clutch housing cover-to-transmission bolts (4)
     
    Left and right side transmission-to-engine cover bolts
     
    Transmission rear mount. Support the transmission with a transmission jack.
     
    Bolts and studs securing the transmission to the engine.
     

  6.  
  7. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch plate and the clutch cover. Remove the transmission from the vehicle.
  8.  
  9. Remove the clutch plate and the clutch cover from the engine flywheel if required.
  10.  

To install:

  1. Install or connect the following:

    Clutch plate and the clutch cover to the engine flywheel, if removed
     

  2.  
  3. Ensure the transmission is positioned in the 3rd or 4th speed gear. Rotate the transmission clockwise onto the clutch hub splines. Install the bolt and the studs securing the transmission to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Install or connect the following:

    Right and left side transmission to engine cover bolts and tighten to 10 ft. lbs. (14 Nm)
     
    Clutch cover-to-transmission bolts and tighten to 10 ft. lbs. (14 Nm)
     
    Transmission rear mount
     
    Clutch line to the slave cylinder
     
    Right side support bracket-to-transmission bolts (2). Tighten to 37 ft. lbs. (50 Nm).
     
    Manual transfer case shift linkage, if removed
     
    Two transfer case shields, if equipped
     
    Front propeller shaft, if equipped
     
    Rear propeller shaft
     
    Shift tower
     
    Transmission with transmission fluid
     
    Shift lever
     

  6.  

Zf S6-650 Transmissions



  1. Shift the transmission into 3rd or 4th speed gear.
  2.  
  3. Remove the shift lever.
  4.  
  5. Raise and suitably support the vehicle.
  6.  
  7. If vehicle is a 2 wheel drive (2WD), remove the rear propeller shaft.
  8.  
  9. If equipped with 4 wheel drive (4WD), remove the transfer case.
  10.  
  11. Disconnect the clutch slave cylinder hydraulic hose quick connect at the master cylinder.
  12.  
  13. Disconnect the clutch slave cylinder line retaining clips.
  14.  
  15. If equipped with a 6.6L engine, disconnect the power take off, backup lamp and vehicle speed sensor connectors.
  16.  
  17. Remove the engine harness clips from the fuel feed/return brackets.
  18.  
  19. Remove the PTO connector from the fuel feed/return bracket.
  20.  
  21. Reposition the harness.
  22.  
  23. Remove the fuel lines from the fuel feed/return brackets.
  24.  
  25. If equipped with a 8.1L engine, disconnect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  26.  
  27. Remove the engine harness clips from the fuel feed/return brackets.
  28.  
  29. Remove the PTO connector from the fuel feed/return bracket.
  30.  
  31. Remove the oxygen sensors connectors from the fuel feed/return hose clip and transmission bracket.
  32.  
  33. Reposition the harness.
  34.  
  35. Remove the fuel lines from the fuel feed/return brackets.
  36.  
  37. If equipped with 4WD, remove the vent hose clip from the bracket.
  38.  
  39. Remove the vent hose clip nut and clip.
  40.  
  41. If equipped with 4WD, remove the vent hose clip from the fuel feed/return bracket.
  42.  
  43. Remove the starter.
  44.  
  45. Remove the exhaust pipe hanger bracket bolts and bracket.
  46.  
  47. Support the transmission with a suitable transmission jack.
  48.  
  49. Remove the transmission support
  50.  
  51. Remove the transmission bolts/studs.
  52.  
  53. Pull the transmission straight back on the clutch hub splines. Do not let the transmission hang from the clutch assembly.
  54.  
  55. Remove the transmission from the vehicle with the clutch hydraulic hose attached to the clutch actuator.
  56.  
  57. Remove the insulator from the top of the transmission.
  58.  

To install:

  1. Install the insulator to the top of the transmission.
    NOTE
    Connect the clutch slave cylinder hose quick connect to the master cylinder before the transmission is fully installed. Failure to connect the hose could cause damage to the clutch pressure plate.

  2.  
  3. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  4.  
  5. Rotate the transmission clockwise onto the clutch hub splines.
  6.  
  7. Position the transmission to the engine. Do not use the transmission bolts to draw up the transmission.
  8.  
  9. Install the transmission studs and tighten to 37 ft. lbs. (50 Nm).
  10.  
  11. Slowly feed the clutch hydraulic hose towards the clutch master cylinder and connect the clutch slave cylinder hydraulic hose quick connect to the master cylinder.
  12.  
  13. Install the transmission support.
  14.  
  15. Remove the transmission jack.
  16.  
  17. Install the exhaust pipe hanger bracket and bolts.
  18.  
  19. Install the starter.
  20.  
  21. If equipped with 4WD, install the vent hose clip to the fuel feed/return bracket.
  22.  
  23. Install the vent hose clip and nut.
  24.  
  25. Install the vent hose clip to the bracket.
  26.  
  27. Install the fuel lines to the fuel feed/return brackets.
  28.  
  29. Position the harness.
  30.  
  31. Install the oxygen sensors connectors to the fuel feed/return hose clip and transmission bracket.
  32.  
  33. Install the PTO connector to the fuel feed/return bracket.
  34.  
  35. Install the engine harness clips to the fuel feed/return brackets.
  36.  
  37. If equipped with a 8.1L engine, connect the power take off, backup lamp, vehicle speed sensor and oxygen sensor connectors.
  38.  
  39. Connect the clutch slave cylinder line retaining clips.
  40.  
  41. If equipped with 4WD, install the transfer case.
  42.  
  43. If equipped with a 6.6L engine, connect the power take off, backup lamp and vehicle speed sensor connectors.
  44.  
  45. If vehicle is a 2WD, install the rear propeller shaft.
  46.  
  47. Lower the vehicle.
  48.  
  49. Install the shift lever.
  50.  
  51. Fill the transmission with fluid.
  52.  
  53. Bleed the clutch hydraulic system, if necessary.
  54.  
  55. Connect the battery cables.
  56.  

 
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