For 1990-2009 cars

#### Tools Required

J 37761 Universal Clutch Alignment Arbor

### Removal Procedure

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable (1).

Important: After removing the gearshift control lever, remove the bolt directly behind the gearshift lever case. This bolt attaches the gearshift lever case to the transfer case and must be removed before the transfer case removal can be performed.

2. Remove the gearshift control lever from the gearshift lever case. Refer to Gearshift Control Lever Replacement .
3. Remove the 4 retainers from the fan shroud at the radiator.
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the following items from the vehicle

• | The 4 bolts

• | The front skid plate

6. Remove the 2 upper transmission-to-engine bolts from the transmission.
7. Place a drain pan or a suitable container underneath the transmission.
8. Remove the transmission oil level/filler plug (2) from the transmission.
9. Remove the transmission drain plug (3) from the transmission and drain the transmission oil.
10. Remove the transmission drain plug (1) from the transmission and drain the transmission oil.
11. Disconnect the backup lamp switch electrical connector (1) from the backup lamp switch.
12. Remove the starter motor electrical connections from the starter motor.
13. Remove the following items from the transmission:

• | The 2 bolts

• | The 1 nut

• | The starter motor

14. Remove the transfer case from the vehicle (Four-Wheel Drive Models). Refer to Transfer Case Replacement in Driveline/Axle.
15. Place index marks on the propeller shaft pinion flange yoke and the differential pinion flange to ensure correct installation.
16. Remove the following items from the vehicle (Two-Wheel Drive Models):

• | The 4 bolts

• | The 4 nuts

• | The rear propeller shaft

17. Disconnect the Vehicle Speed Sensor.
18. Remove the Three-Way Catalytic Converter (TWC) and the muffler/tail pipe assembly from the vehicle. Refer to Front Pipe Replacement in Engine Exhaust.
19. Remove the drain pan from underneath the transmission.
20. Support the transmission with a suitable hydraulic jack.
21. Remove the 2 bolts (2) from the rear transmission mount (1) (Two-Wheel Drive Models).
22. Remove the following items from the vehicle:

• | The 4 bolts

• | The rear transmission crossmember

• | Remove the hydraulic slave cylinder and set aside. Refer to Clutch Actuator Cylinder Replacement .

• | Remove the 2 bolts from the flywheel inspection cover.

23. Remove the 2 lower transmission-to-engine nuts (2) from the transmission.
24. Remove the transmission from the vehicle by carefully moving the transmission away from the engine toward the rear of the vehicle until the input shaft is clear of the clutch pressure plate cover. Then, very slowly lower the transmission jack making sure there are no obstructions.
25. Inspect the transmission. For disassembly and inspection procedures, refer to Transmission/Transaxle/Transfer Case Unit Repair Manual.

### Installation Procedure

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 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.

Notice: 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.

3. Install the 2 lower transmission-to-engine nuts into the transmission.

Tighten
Tighten the 2 lower transmission-to-engine nuts to 100 N·m (72 lb ft).

4. Install the 2 bolts (2) into the right transmission-to-engine reinforcement brace (1).

Tighten
Tighten the right transmission-to-engine brace bolts to 100 N·m (72 lb ft).

5. Install the flywheel inspection cover and the 2 bolts (2) into the left transmission-to-engine reinforcement brace (1).

Tighten
Tighten the left transmission-to-engine reinforcement brace bolts to 100 N·m (72 lb ft).

6. Install the breather hose to the gearshift lever case and secure with 1 clamp.
7. Install the 2 bolts into the flywheel inspection cover.

Tighten
Tighten the flywheel inspection cover bolts to 10 N·m (89 lb in).

8. Install the following items onto the clutch release shaft making sure to match the alignment marks on both and secure with 1 bolt and 1 nut:

• | The bolt

• | The nut

• | The clutch release lever

Tighten
Tighten the clutch release lever bolt and the nut to 24 N·m (17 lb ft).

9. Install the rear transmission crossmember to the vehicle and secure with the 4 bolts (Two-Wheel Drive Models).

Tighten
Tighten the rear transmission crossmember bolts to 60 N·m (44 lb ft).

10. Install the 2 bolts (2) into the rear transmission mount (1) (Two-Wheel Drive Models).

Tighten
Tighten the rear transmission crossmember bolts to 60 N·m (44 lb ft).

11. Remove the hydraulic jack from underneath the transmission.
12. Install the Three-Way Catalytic Converter (TWC) and the muffler/tail pipe assembly to the vehicle. Refer to Front Pipe Replacement in Engine Exhaust.
13. Install the vehicle speed sensor (2).

Install the front skid plate to the vehicle and secure with the 4 bolts (if equipped).

Tighten
Tighten the front skid plate bolts to 54 N·m (40 lb ft).

14. Install the rear propeller shaft into the vehicle aligning the index marks made during removal and secure with the 4 nuts and the 4 bolts.

Tighten
Tighten the rear propeller shaft nuts and bolts to 50 N·m (37 lb ft).

15. Install the transfer case into the vehicle (Four-Wheel Drive Models). Refer to Transfer Case Replacement in Driveline/Axle.
16. Install the starter motor to the transmission and secure with the 2 bolts and 1 nut.

Tighten
Tighten the starter motor bolts and nut to 30 N·m (22 lb ft).

17. Install the starter motor electrical connections to the starter motor.
18. Install the backup lamp switch electrical connector (1) to the backup lamp switch.
19. 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
Tighten the transmission drain plug to 28 N·m (20 lb ft).

20. 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.

Apply the GM P/N 12346004, or equivalent, to the threaded portion of the transmission oil level/filler plug (2).

21. Install the transmission oil level/filler plug (2) into the transmission.

Tighten
Tighten the transmission oil level/filler plug to 28 N·m (20 lb ft).

22. Lower the vehicle.
23. Install the 2 upper transmission-to-engine bolts into the transmission.

Tighten
Tighten the upper transmission-to-engine bolts to 100 N·m (72 lb ft).

24. Install the 4 bolts from the fan shroud at the radiator.

Tighten
Tighten the fan shroud bolts to 10 N·m (89 lb in).

25. Install the transfer case gearshift control lever into the transfer case (Four-Wheel Drive Models). Refer to Gearshift Control Lever Replacement .
26. Install the 1 bolt (2) into the rear of the gearshift lever case (Four-Wheel Drive Models).

Tighten
Tighten the gearshift lever case bolt to 17 N·m (12 lb ft).

27. Install the gearshift control lever into the gearshift lever case. Refer to Gearshift Control Lever Replacement .

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

28. Connect the negative battery cable.