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Automatic Transmission Removal & Installation Chevrolet Chevy Express H2500

Automatic Trans 11 illustrations ~1583 words

APPLICATION

ApplicationTransmission Model (RPO Code)
Chevrolet
Express4L60-E (M30) Or 4L80-E (MT1)
Cutaway & RV Cutaway4L80-E (MT1)
GMC
Savana4L60-E (M30) Or 4L80-E (MT1)
Savana Camper Special & Savana Special4L80-E (MT1)

TRANSMISSION APPLICATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
CAUTIONBefore servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Scheme 74

Scheme 74: Removal (4L60-E)
Scheme 74: Removal (4L60-E)

Scheme 75

Scheme 75
Scheme 75

Scheme 76

Scheme 76
Scheme 76

Scheme 77

Scheme 77
Scheme 77
  1. Disconnect the battery negative (-) cable assembly from the battery negative terminal.
  2. Raise the vehicle.
  3. Support the vehicle with safety stands.
  4. Disconnect the range selector cable from the transmission bracket and from the range selector lever. (Scheme 74)
  5. If equipped with All Wheel Drive (AWD), remove the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
  6. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  7. Support the transmission with a transmission jack.
  8. Remove the transmission support. See «TRANSMISSION SUPPORT»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation).
  9. Remove the exhaust pipe from the exhaust manifolds and the muffler assembly from the exhaust pipe.
  10. Remove the starter motor. See appropriate STARTERS article in ELECTRICAL.
  11. Remove the converter sight shield. (Scheme 75)
  12. Mark the flywheel and the torque converter alignment.
  13. Remove the bolts that attach the torque converter to the engine flywheel. (Scheme 76)
  14. Remove the transmission vent hose and the wiring harness from the transmission.
  15. Remove the transmission fluid fill tube and the fill tube seal from the transmission. See FILLER TUBE under REMOVAL & INSTALLATION in appropriate SERVICING article.
  16. Plug the fluid fill tube opening in the transmission.
  17. Disconnect the transmission oil cooler pipes from the transmission.
  18. Plug the transmission oil cooler pipe connectors in the transmission case.
  19. Disconnect the wiring harness connectors from the transmission Vehicle Speed Sensor (VSS) and the Park/Neutral Position (PNP) switch. (Scheme 77)
  20. Remove all vehicle harness wires, harness clips, tubes, brackets, and lines that may interfere with the removal of the transmission from the vehicle.
  21. Remove the studs and the bolts securing the transmission to the engine. (Scheme 78)
  22. Pull the transmission straight back.
  23. Remove the transmission from the vehicle.
  24. Inspect all the components for wear and damage.
  25. Inspect all the seals and the fittings for signs of wear.
  26. Inspect the torque converter for stripped or broken weld nuts.
  27. Inspect the transmission case for cracks.

Installation (4L60-E)

  1. Support the transmission with a transmission jack.
  2. Raise the transmission into place.
  3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter.
  4. Install the bolts that secure the transmission to the engine. (Scheme 78) Tighten the studs and the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  5. Install the bolts securing the torque converter to the flywheel as follows: First tighten all the bolts finger tight in order to insure proper converter seating. (Scheme 76) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  6. If equipped with All Wheel Drive (AWD), install the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
  7. Install the wiring harness connectors to the VSS and the PNP switch. (Scheme 77)
  8. Position and install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal.
  9. Install the transmission fluid fill tube and the fill tube seal. See FILLER TUBE under REMOVAL & INSTALLATION in appropriate SERVICING article.
  10. Install the transmission vent hose and the wiring harness to the transmission.
  11. Install the sight shield. (Scheme 75)
  12. Install the starter motor. See appropriate STARTERS article in ELECTRICAL.
  13. Install the exhaust pipe to the exhaust manifolds and the muffler assembly to the exhaust pipe.
  14. Install the transmission support. See «TRANSMISSION SUPPORT»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation).
  15. Remove the transmission jack and the engine support stands.
  16. Install the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  17. Install the transmission range select cable to the transmission range select lever and the bracket. (Scheme 74)
  18. Install the transmission oil cooler pipes.
  19. Flush the transmission oil cooler and the pipes whenever you remove the transmission for overhaul, or replacement of the torque converter, the pump, or the transmission case. See OIL COOLER FLUSHING under LUBRICATION in appropriate SERVICING article.
  20. Remove the safety stands.
  21. Lower the vehicle.
  22. Fill the transmission with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING article.
  23. Connect the negative (-) battery cable assembly to the negative battery terminal. Tighten the terminal bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).

Scheme 78

Scheme 78: Removal (4L80-E)
Scheme 78: Removal (4L80-E)

Scheme 79

Scheme 79
Scheme 79
  1. Disconnect the battery negative (-) cable assembly from the battery negative terminal.
  2. Raise the vehicle.
  3. Support the vehicle with safety stands.
  4. If equipped with All Wheel Drive (AWD), remove the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
  5. Disconnect the range selector cable from the transmission bracket and from the range selector lever. (Scheme 74)
  6. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  7. Support the transmission with a transmission jack.
  8. Remove the transmission support.
  9. Remove the exhaust pipe from the exhaust manifolds and the muffler assembly from the exhaust pipe.
  10. Remove the starter motor. See appropriate STARTERS article in ELECTRICAL.
  11. Mark the flywheel and the torque converter alignment.
  12. Remove the bolts that attach the torque converter-to-engine flywheel. (Scheme 79)
  13. Remove the transmission vent hose and the wiring harness from the transmission.
  14. Remove the transmission fluid fill tube and the fill tube seal from the transmission. See FILLER TUBE under REMOVAL & INSTALLATION in appropriate SERVICING article.
  15. Plug the fluid fill tube opening in the transmission.
  16. Disconnect the transmission oil cooler pipes from the transmission.
  17. Plug the transmission oil cooler pipe connectors in the transmission case.
  18. Disconnect the wiring harness connectors from the transmission VSS and the PNP switch.
  19. Remove all vehicle harness wires, harness clips, tubes, brackets, and lines that may interfere with the removal of the transmission from the vehicle. (Scheme 77)
  20. Remove the studs and the bolts securing the transmission to the engine. (Scheme 80)
  21. Pull the transmission straight back.
  22. Remove the transmission from the vehicle.
  23. Inspect all the components for wear and damage.
  24. Inspect all the seals and the fittings for signs of wear.
  25. Inspect the torque converter for stripped or broken weld nuts.
  26. Inspect the transmission case for cracks.

Installation (4L80-E)

  1. Support the transmission with a transmission jack.
  2. Raise the transmission into place.
  3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter.
  4. Install the bolts that secure the transmission to the engine. (Scheme 80) Tighten the studs and the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  5. Install the bolts securing the torque converter to the flywheel as follows: First tighten all the bolts finger tight in order to insure proper converter seating. (Scheme 79) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  6. If equipped with All Wheel Drive (AWD), install the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
  7. Install the wiring harness connectors to the VSS and the PNP switch. (Scheme 77)
  8. Position and install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal.
  9. Remove the two plugs from the transmission case cooling line connectors.
  10. Install the transmission oil cooler pipes.
  11. Install the transmission fluid fill tube and the fill tube seal. See FILLER TUBE under REMOVAL & INSTALLATION in appropriate SERVICING article.
  12. Install the transmission vent hose and the wiring harness to the transmission.
  13. Install the starter motor. See appropriate STARTERS article in ELECTRICAL.
  14. Install the exhaust pipe to the exhaust manifolds and the muffler assembly to the exhaust pipe.
  15. Install the transmission support. See «TRANSMISSION SUPPORT»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation).
  16. Remove the transmission jack and the engine support stands.
  17. Install the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  18. Install the transmission range select cable to the transmission range select lever and the bracket. (Scheme 74)
  19. Flush the transmission oil cooler and the pipes whenever you remove the transmission for overhaul, or replacement of the torque converter, the pump, or the transmission case. See OIL COOLER FLUSHING under LUBRICATION in appropriate SERVICING article.
  20. Remove the safety stands.
  21. Lower the vehicle.
  22. Fill the transmission with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING article.
  23. Connect the negative (-) battery cable assembly to the negative battery terminal. Tighten the terminal bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  1. Raise the vehicle.
  2. Support the transmission with a safety stand.
  3. Remove the brake combination valve-to-transmission support mounting bolt. (Scheme 81)
  4. Remove the fuel filter bracket-to-transmission support retaining bolts. (Scheme 82)
  5. Remove the transmission mount-to-transmission support retaining nut. (Scheme 83)or (Scheme 84).
  6. Remove the transmission support-to-frame mounting bolts. see scheme 12
  7. Remove the transmission support from the vehicle.

Scheme 80

Scheme 80
Scheme 80

Scheme 81

Scheme 81
Scheme 81

Scheme 82

Scheme 82
Scheme 82

Scheme 83

Scheme 83
Scheme 83

Scheme 84

Scheme 84
Scheme 84
  1. Install the transmission support to the vehicle. see scheme 12
  2. Install the transmission support-to-frame mounting bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  3. Install the transmission mount-to-transmission support retaining nuts. (Scheme 83)or (Scheme 84). Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  4. Install the fuel filter bracket-to-transmission support retaining bolts. (Scheme 82) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  5. Install the brake combination valve-to-transmission support mounting bolt. (Scheme 81) Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-removal-installation__torque-specifications).
  6. Remove the safety stands.
  7. Lower the vehicle.

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Heat Shield-To-Transmission Bolt13 (17)
Fuel Filter Bracket-To-Transmission Support Retaining Bolts22 (30)
Oil Level Indicator Tube Brackets-To-Engine (4L80-E)
Bolt35 (47)
Nut18 (25)
Oil Level Indicator Tube-To-Transmission Stud18 (25)
PNP Switch-To-Transmission Bolts18 (25)
Torque Converter-To-Flywheel Bolts46 (63)
Transfer Case Mounting Nuts37 (50)
Transmission Oil Cooler Pipe Fitting26-30 (35-41)
Transmission-To-Engine Studs & Bolts34 (47)
Transmission Mount-To-Transmission Support Retaining Nuts44 (60)
Transmission Support-To-Frame Mounting Bolts
Cutaway48 (65)
Except Cutaway50 (66)
INCH Lbs. (N.m)
Battery Cable Terminal133 (15)
Brake Combination Valve-To-Transmission Support Mounting Bolt89 (10)
Oil Level Indicator Tube Brackets-To-Engine (4L60-E)53 (6)
Oil Level Indicator Tube Brackets-To-Transmission (4L60-E)53 (6)

TORQUE SPECIFICATIONS

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