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Automatic Transmission - Removal & Installation - Allison: Application Chevrolet Silverado 2500

Automatic Trans 28 illustrations ~1978 words

APPLICATION

ApplicationEngine SizeTransmission Model (RPO Code)
Chevrolet
Cab & Chassis Silverado 3500, Silverado 2500 HD & Silverado 35006.6L Or 8.1LLCT 1000 (M74)
GMC
Cab & Chassis Sierra 3500, Sierra 2500 HD & Sierra 35006.6L Or 8.1LLCT 1000 (M74)

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.
CAUTIONIf replacing a failed transmission, the "FastLearn" (adapt) procedure must be performed. This can be done in one step using a scan tool. If this procedure is not done, the Transmission Control Module's (TCM) adaptive values will still be at the settings that it learned for the old transmission, and will be in slow adaptive mode. Under these conditions, it would take an unacceptably long time for the adaptive values to converge to levels suitable for the new transmission.

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 563

Scheme 563: Removal (6.6L)
Scheme 563: Removal (6.6L)

Scheme 564

Scheme 564
Scheme 564

Scheme 565

Scheme 565
Scheme 565

Scheme 566

Scheme 566
Scheme 566

Scheme 567

Scheme 567
Scheme 567

Scheme 568

Scheme 568
Scheme 568

Scheme 569

Scheme 569
Scheme 569

Scheme 570

Scheme 570
Scheme 570

Scheme 571

Scheme 571
Scheme 571

Scheme 572

Scheme 572
Scheme 572

Scheme 573

Scheme 573
Scheme 573

Scheme 574

Scheme 574
Scheme 574

Scheme 575

Scheme 575
Scheme 575

Scheme 576

Scheme 576
Scheme 576

Scheme 577

Scheme 577
Scheme 577

Scheme 578

Scheme 578
Scheme 578

Scheme 579

Scheme 579
Scheme 579

Scheme 580

Scheme 580
Scheme 580

Scheme 581

Scheme 581
Scheme 581

Scheme 582

Scheme 582
Scheme 582

Scheme 583

Scheme 583
Scheme 583
  1. Disconnect both of the negative (-) battery cables.
  2. Remove the transmission fluid level indicator.
  3. Raise the vehicle until the right front wheel and tire can be removed.
  4. Remove the right front wheel and tire.
  5. Remove the right front wheel house inner panel retainers (2). (Scheme 563)
  6. Disconnect any harness retainers attached to the inner panel.
  7. Remove the inner panel (2).
  8. Remove the positive (+) battery cable nut and cable from the starter.
  9. Remove the solenoid nut and wire from the starter. (Scheme 564)
  10. Remove the starter motor bolts and reposition the starter. (Scheme 565)
  11. Remove the engine protection shield bolts and shield. (Scheme 566)
  12. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts through the starter opening. Have an assistant rotate the engine while aligning the bolts.
  13. Remove the torque converter bolts. (Scheme 567)
  14. Completely raise the vehicle.
  15. Drain the transmission fluid. See LUBRICATION in appropriate SERVICING article.
  16. Disconnect the shift cable from the selector lever ball stud (5) and remove the cable from the bracket (3). (Scheme 568)
  17. Remove the shift cable bracket bolts and bracket (2) from the transmission. (Scheme 569)
  18. Reposition the bracket with the cable attached off to the side.
  19. Remove the fuel line retainer (1) bolts on the left side of the transmission. (Scheme 570)
  20. Remove the fuel line bracket nut from the converter housing stud. (Scheme 571)
  21. Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. (Scheme 572)
  22. Disconnect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4 wheel drive (4WD), the output speed sensor is located on the transfer case and will be disconnected later. (Scheme 572)
  23. Disconnect the transmission main electrical connector. The Connector Removal Tool (J-44257) may be used, but is not required. (Scheme 573)
  24. Disconnect the Park/Neutral Position (PNP) switch electrical connector.
  25. Remove the exhaust hanger bolts and reposition the hanger. (Scheme 574)
  26. If the vehicle is a 2 wheel drive (2WD), remove the drive shaft. See appropriate DRIVE SHAFT & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  27. Support the transmission with a transmission jack.
  28. If the vehicle is a 2WD, remove the transmission mount nuts. (Scheme 575)
  29. If the vehicle is a 2WD, remove the transmission support bracket bolts. (Scheme 576)
  30. If the vehicle is a 2WD, remove the transmission support bolts and nuts. (Scheme 576)
  31. Remove the transmission mount bolts (1). (Scheme 577)
  32. Remove the transmission mount.
  33. If the vehicle is equipped with 4WD, remove the transfer case. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES.
  34. Reposition any wiring harness branches out of the way.
  35. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other related components. (Scheme 578)
  36. Disconnect the transmission oil cooler lines (1 and 2) from the transmission. (Scheme 579)
  37. Plug the transmission oil cooler line fittings in the transmission case, if necessary.
  38. If the vehicle is equipped with a Power Take Off (PTO) unit, disconnect and/or remove any necessary components to facilitate transmission removal.
  39. Remove the transmission fill tube nuts from the converter housing studs. (Scheme 580)
  40. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the bracket. (Scheme 581)
  41. Remove the remaining converter housing bolts and studs. (Scheme 582)
  42. Separate the transmission from the engine.
  43. Install Converter Holding Strap (J-21366) to the converter housing in order to keep the torque converter from sliding off of the turbine shaft. (Scheme 583)
  44. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
  45. Remove the converter holding strap.

Scheme 584

Scheme 584: Installation (6.6L)
Scheme 584: Installation (6.6L)

Scheme 585

Scheme 585
Scheme 585
  1. Install converter holding strap to the converter housing in order to keep the torque converter from sliding off of the turbine shaft. (Scheme 583)
  2. Raise the transmission into place while simultaneously installing the transmission fill tube.
  3. Remove the converter holding strap.
  4. Align the transmission with the engine using the alignment dowels located at the rear of the engine. (Scheme 582)
  5. Install the converter housing bolts and studs. Tighten the bolts and studs to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  6. Install the wire harness/vent tube bracket and nut to the converter housing stud. (Scheme 581) Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  7. Install the transmission fill tube and nuts to the converter housing studs. (Scheme 580) Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  8. If the vehicle is equipped with a PTO unit, connect and/or install the components at this time.
  9. Remove the safety chain from around the transmission. (Scheme 578)
  10. Install the transfer case, if the vehicle is equipped with 4WD.
  11. If the vehicle is a 2WD, install the transmission mount.
  12. If the vehicle is a 2WD, install the transmission mount bolts (1). (Scheme 577) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  13. Install the transmission support.
  14. If the vehicle is a 2WD, install the transmission support bolts and nuts.
  15. If the vehicle is a 2WD, install the transmission support bracket bolts. (Scheme 576) Tighten the bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  16. If the vehicle is a 2WD, install the transmission mount nuts. (Scheme 575) Tighten the nuts specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  17. If the vehicle is a 2WD, install the transmission mount nuts. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  18. If the vehicle is a 2WD, install the drive shaft.
  19. Position the exhaust hanger and install the bolts. (Scheme 574) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  20. Position the wiring harness branches.
  21. Connect the PNP switch electrical connectors.
  22. Connect the transmission main electrical connector (2). (Scheme 584)
  23. Connect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and has been connected during the transfer case installation. (Scheme 572)
  24. Connect the turbine speed sensor (1) and the input speed sensor (2) electrical connectors.
  25. Install the fuel line bracket and nut to the transmission converter housing stud. (Scheme 571) Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  26. Install the fuel line retainer (1) and bolts to the left side of the transmission. (Scheme 570) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  27. Install the shift cable bracket (2) and bolts to the transmission. (Scheme 569) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  28. Install the shift cable to the bracket (3) and the selector lever ball stud (5). (Scheme 568)
  29. Remove the access hole cover (1) on the converter housing in order to rotate the converter and align the first torque converter bolt. (Scheme 585)
  30. Install the torque converter bolts. (Scheme 567) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  31. Install the converter housing access hole cover.
  32. Install the engine protection shield and bolts. (Scheme 566) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  33. Position and install the starter motor bolts. See appropriate STARTERS article in ELECTRICAL. (Scheme 565) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  34. Install the solenoid wire and nut to the starter. (Scheme 564) Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  35. Install the positive battery cable and nut to the starter. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-154779-S11397803392003052300000).
  36. Install the inner panel (2).
  37. Connect any harness retainers to the inner panel.
  38. Install the right front wheel house inner panel retainers (2). (Scheme 563)
  39. Install the right front wheel and tire.
  40. Remove the plugs from the transmission oil cooler line fittings in the transmission case, if necessary.
  41. Flush the transmission oil cooler and lines, if necessary.
  42. Connect the transmission oil cooler lines (1 and 2) to the transmission. (Scheme 579)
  43. Lower the vehicle.
  44. Connect both negative (-) battery cables.
  45. Fill the transmission with new transmission fluid.
  46. Install the transmission fluid level indicator.
  47. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. See PROGRAMMING in appropriate DIAGNOSIS article.

Scheme 586

Scheme 586: Removal (8.1L)
Scheme 586: Removal (8.1L)

Scheme 587

Scheme 587
Scheme 587

Scheme 588

Scheme 588
Scheme 588

Scheme 589

Scheme 589
Scheme 589

Scheme 590

Scheme 590
Scheme 590
  1. Disconnect the negative (-) battery cable.
  2. Remove the transmission fluid level indicator.
  3. Raise and suitably support the vehicle.
  4. Remove the engine protection shield bolts and shield. (Scheme 566)
  5. Remove the starter motor bolts and position the starter motor aside. (Scheme 586)
  6. Drain the transmission fluid, if necessary.
  7. If the vehicle is a 2 wheel drive (2WD), remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINT article in DRIVELINE/AXLES.
  8. Support the transmission with a transmission jack.
  9. If the vehicle is a 2WD, remove the transmission mount nuts. (Scheme 575)
  10. If the vehicle is a 2WD, remove the transmission support bracket bolts. (Scheme 576)
  11. If the vehicle is a 2WD, remove the transmission support bolts and nuts.
  12. If the vehicle is a 2WD, remove the transmission support.
  13. If the vehicle is equipped with 4 wheel drive (4WD), remove the transfer case.
  14. Remove the transmission mount bolts (1). (Scheme 577)
  15. Remove the transmission mount.
  16. Disconnect the shift cable from the selector lever ball stud (5) and remove the cable from the bracket (3). (Scheme 568)
  17. Remove the shift cable bracket bolts and bracket (2) from the transmission. (Scheme 569)
  18. Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. (Scheme 572)
  19. Disconnect the output speed sensor (3) electrical connector. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and will already be disconnected.
  20. Disconnect the transmission main electrical connector. The connector removal tool may be used, but is not required. (Scheme 573)
  21. Disconnect the park neutral position (PNP) switch electrical connector.
  22. Remove the fuel line retainer (1) bolts on the left side of the transmission. (Scheme 570)
  23. Remove the transmission heat shield bolt and nut (4 and 5) and shield (3). (Scheme 587)
  24. Remove the exhaust pipe hanger bolts and reposition the hanger. (Scheme 574)
  25. Remove the transmission heat shield bolts (2) and shield (1). (Scheme 587)
  26. Remove the converter housing inspection cover bolts and cover. (Scheme 588)
  27. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts through the starter opening. Have an assistant rotate the engine while aligning the bolts.
  28. Remove the torque converter bolts (3). (Scheme 589)
  29. Remove the transmission fill tube nuts from the converter housing studs. (Scheme 580)
  30. Remove the fuel line bracket nut from the converter housing stud. (Scheme 571)
  31. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the bracket. (Scheme 581)
  32. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other related components. (Scheme 578)
  33. Disconnect the transmission oil cooler lines (1 and 2) from the transmission. (Scheme 579)
  34. Plug the transmission oil cooler line fittings in the transmission case.
  35. If the vehicle is equipped with a Power Take Off unit (PTO), disconnect and/or remove any necessary components to facilitate transmission removal.
  36. Remove the remaining converter housing bolts and studs. (Scheme 590)
  37. Separate the transmission from the engine.
  38. Install converter holding strap to the converter housing in order to keep the torque converter from sliding off of the turbine shaft. (Scheme 583)
  39. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
  40. Remove the converter holding strap.

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