Transmission Installation
^ Tools Required- J 37761 Clutch Alignment Arbor
1. Inspect the clutch alignment by inserting the J 37761 through the clutch disc and into the crankshaft pilot bearing. If the J 37761 does not fit through the clutch disc and into the pilot bearing assembly smoothly, the clutch disc may be misaligned. For clutch disassembly and inspection procedures, refer to Clutch Assembly Replacement in Clutch, M/T and align if necessary.
2. Install the transmission to the engine by raising the transmission into position and moving the transmission toward the engine while simultaneously inserting the transmission input shaft through the pressure plate cover (1) and the clutch disc into the crankshaft pilot bearing.
3. Install the two lower transmission-to-engine nuts into the transmission.
^ Tighten the two lower transmission-to-engine nuts to 100 Nm (72 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Install the two bolts (2) into the right transmission-to-engine reinforcement brace (1).
^ Tighten the right transmission-to-engine brace bolts to 100 Nm (72 ft. lbs.).
5. Install the flywheel inspection cover and the two bolts (2) into the left transmission-to-engine reinforcement brace (1).
^ Tighten the left transmission-to-engine reinforcement brace bolts to 100 Nm (72 ft. lbs.).
6. Install the breather hose to the gearshift lever case and secure with one clamp.
7. Raise the transmission slowly until the engine is no longer in contact with the wood block between the bulkhead (2) and the gear distributor housing.
8. Remove the wood block.
9. Install the two bolts into the flywheel inspection cover.
^ Tighten the flywheel inspection cover bolts to 10 Nm (89 inch lbs.).
10. Install the following items onto the clutch release shaft making sure to match the alignment marks on both and secure with one bolt and one nut:
^ The bolt.
^ The nut.
^ The clutch release lever.
^ Tighten the clutch release lever bolt and the nut to24 Nm (17 ft. lbs.).
11. Install the rear transmission crossmember to the vehicle and secure with the four bolts (Two-Wheel Drive Models).
^ Tighten the rear transmission crossmember bolts to 60 Nm (44 ft. lbs.).
12. Install the two bolts (2) into the rear transmission mount (1) (Two-Wheel Drive Models).
^ Tighten the rear transmission crossmember bolts to 60 Nm (44 ft. lbs.).
13. Remove the hydraulic jack from underneath the transmission.
14. Install the Three-Way Catalytic Converter (TWC) and the muffler/tail pipe assembly to the vehicle.
15. Remove the speedometer driven gear case retaining bolt (2).
Install the ground wire (1) to the speedometer driven gear case and secure with one bolt.
^ Tighten the speedometer driven gear case retaining bolt to 12 Nm (106 inch lbs.).
16. Install the speedometer cable (3) from the speedometer driven gear case (Two-Wheel Drive Models)
17. Install the front skid plate to the vehicle and secure with the four bolts (if equipped).
^ Tighten the front skid plate bolts to 54 Nm (40 ft. lbs.).
18. Install the rear propeller shaft into the vehicle aligning the index marks made during removal and secure with the four nuts and the four bolts (Two-Wheel Drive Models).
^ Tighten the rear propeller shaft nuts and bolts to 50 Nm (37 ft. lbs.).
19. Install the transfer case into the vehicle (Four-Wheel Drive Models).
20. Install the starter motor to the transmission and secure with the two bolts and one nut.
^ Tighten the starter motor bolts and nut to 30 Nm (22 ft. lbs.).
21. Install the starter motor electrical connections to the starter motor.
22. Install the backup lamp switch electrical connector (1) to the backup lamp switch.
23. Apply the GM P/N 12346004, or equivalent, to the threaded portion of the transmission drain plug (3). Install the transmission drain plug (3) into the transmission.
^ Tighten the transmission drain plug to 28 Nm (20 ft. lbs.).
24. Add approximately 1.5 liters (1.6 quarts) of synthetic 75W-90 GL4 lubricant, or equivalent, into the transmission oil level/filler plug hole. The oil level should be even with the bottom of the transmission oil level/filler plug hole (Two-Wheel Drive Models).
25. Apply the GM P/N 12346004, or equivalent, to the threaded portion of the transmission oil level/filler plug (2).
26. Install the transmission oil level/filler plug (2) into the transmission.
^ Tighten the transmission oil level/filler plug to 28 Nm (20 ft. lbs.).
27. Lower the vehicle.
28. Install the two upper transmission-to-engine bolts into the transmission.
^ Tighten the upper transmission-to-engine bolts to 100 Nm (72 ft. lbs.).
29. Install the four bolts from the fan shroud at the radiator.
^ Tighten the fan shroud bolts to 10 Nm (89 inch lbs.).
30. Install the transfer case gearshift control lever into the transfer case (Four-Wheel Drive Models). Refer to Gearshift Control Lever Installation.
31. Install the one bolt (2) into the rear of the gearshift lever case (Four-Wheel Drive Models).
^ Tighten the gearshift lever case bolt to 17 Nm (12 ft. lbs.).
32. Install the gearshift control lever into the gearshift lever case. Refer to Gearshift Control Lever Installation.
33. Connect the negative battery cable.