At Removal & Installation

2003 Chevrolet Silverado 1500
2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Avalanche, Escalade, Sierra, Silverado, Suburban,
Tahoe & Yukon (4L60-E & 4L65-E)
2002-03 AUTOMATIC TRANSMISSIONS

Removal & Installation - Avalanche, Escalade, Sierra, Silverado, Suburban, Tahoe & Yukon
(4L60-E & 4L65-E)
APPLICATION
TRANSMISSION APPLICATION
Application
Cadillac
Escalade
5.3L
6.0L
Escalade ESV 6.0L (2003)
Escalade EXT 6.0L
Chevrolet
Avalanche 5.3L
Silverado 1500
4.3L, 4.8L & 5.3L
6.0L
Suburban 5.3L
Tahoe 4.8L & 5.3L
GMC
Sierra 1500
4.3L, 4.8L & 5.3L
6.0L
Yukon 4.8L & 5.3L
Yukon XL 5.3L
Transmission Model (RPO Code)
4L60-E (M30)
4L65-E (M32)
4L65-E (M32)
4L65-E (M32)
4L60-E (M30)
4L60-E (M30)
4L65-E (M32)
4L60-E (M30)
4L60-E (M30)
4L60-E (M30)
4L65-E (M32)
4L60-E (M30)
4L60-E (M30)
REMOVAL & INSTALLATION

WARNING: Vehicle 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.
CAUTION: When 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
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2005 Mitchell Repair Information Company, LLC.

GENERAL INFORMATION before disconnecting battery.

CAUTION: 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.
TRANSMISSION
Removal
1. Record preset radio stations. Turn off lamps, accessories and ignition. Disconnect the negative battery
cable.
2. Drain the transmission fluid. See DRAINING & REFILLING under LUBRICATION in SERVICING AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E &
4L65-E) article.
3. Remove the rear driveshaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in
DRIVELINE/AXLES.
4. Support the transmission with a transmission jack.
5. Remove the transmission mount nuts. See Fig. 1 .
6. Remove the transmission support bolts and nuts. See Fig. 2 .
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Fig. 1: Removing/Installing Transmission Mount Nuts

Courtesy of GM
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Fig. 2: Removing/Installing Transmission Support Bolts & Nuts

Courtesy of GM
7.
8.
9.
10.
Raise the transmission slightly and remove the transmission support from the vehicle.
Remove the exhaust pipe.
Remove the starter motor. See appropriate STARTERS article in ELECTRICAL.
If equipped, remove the transfer case. See appropriate REMOVAL & INSTALLATION article as
follows:
z For Escalade, Escalade EXT, Yukon Denali and Yukon XL, see TRANSFER CASE ASSEMBLY
REPLACEMENT .
z See REMOVAL & INSTALLATION - SIERRA & SILVERADO article in TRANSFER
CASES.
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For Avalanche, Tahoe, Yukon & Yukon XL, see TRANSFER CASE ASSEMBLY
REPLACEMENT .
11. Remove the transmission mount bolts and mount. See Fig. 3 .
z
Fig. 3: Removing/Installing Transmission Bolts & Mount

Courtesy of GM
12. Ensure the transmission manual shaft is positioned in mechanical park.
13. Remove the retainer that secures the cable to the bracket. See Fig. 4 .
14. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). See Fig.
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5.
Fig. 4: Removing/Installing Cable-To-Bracket Retainer

Courtesy of GM
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Fig. 5: Disconnecting Range Selector Cable

Courtesy of GM
15. Depress the tangs and remove the cable from the bracket.
16. Remove the exhaust hanger bracket bolts and bracket. See Fig. 6 .
17. Remove the harness clip (1) from the fuel line bracket. See Fig. 7 .
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Fig. 6: Removing/Installing Exhaust Hanger Bracket

Courtesy of GM
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Fig. 7: Identifying Harness Clip & PNP Switch

Courtesy of GM
18. Disconnect the Park/Neutral Position (PNP) switch electrical connectors (2). See Fig. 7 . See
PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION in SERVICING AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E &
4L65-E) article.
19. Disconnect the main electrical connector (1). See Fig. 8 .
20. Disconnect the Vehicle Speed Sensor (VSS) electrical connector (2). See Fig. 8 .
21. Remove the bolt that secures the fuel line bracket to the left side of the transmission. See Fig. 9 .
22. Remove the torque converter bolts. See Fig. 10 .
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Fig. 8: Identifying Main Electrical Connector & VSS

Courtesy of GENERAL MOTORS CORP.
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Fig. 9: Removing/Installing Fuel Line Bracket-To-Left Side Transmission Bolt

Courtesy of GM
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Fig. 10: Identifying Torque Converter Bolts

Courtesy of GM
23. Disconnect the transmission oil cooler lines. See Fig. 11 . For additional information, see OIL COOLER
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24.
25.
26.
27.
LINE QUICK CONNECT FITTING under REMOVAL & INSTALLATION in SERVICING AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E &
4L65-E) article.
Plug the transmission oil cooler line fittings.
Remove the fuel feed/return and Evaporative Emission (EVAP) return pipe bracket nut. See Fig. 12 .
Remove the lower right transmission bolt and stud. See Fig. 13 .
Remove the remaining transmission studs and bolt. See Fig. 14 .
Fig. 11: Disconnecting Transmission Oil Cooler Lines

Courtesy of GM
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Fig. 12: Removing/Installing EVAP Return Pipe Bracket Nut

Courtesy of GM
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Fig. 13: Removing Lower Right Transmission Bolt & Stud

Courtesy of GM
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Fig. 14: Removing/Installing Remaining Transmission Studs & Bolts

Courtesy of GM
28. Install the Converter Holding Strap (J-21366) onto the transmission in order to retain the torque
converter.
29. Pull the transmission straight back.
30. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.
31. Install the converter holding strap to the bellhousing in order to retain the torque converter.
32. Flush the transmission oil cooler and cooling lines if necessary. See OIL COOLER FLUSHING &
FLOW CHECK under LUBRICATION in SERVICING - AVALANCHE, ESCALADE, SIERRA,
SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E & 4L65-E) article.
Installation
1. Raise the transmission into place while simultaneously installing the fluid indicator tube.
2. Remove the converter holding strap.
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3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the
torque converter. The torque converter must rotate freely by hand.
4. Install transmission studs and bolt. See Fig. 14 . Tighten the bolt/studs to specification. See TORQUE
SPECIFICATIONS .
5. Install the lower right transmission stud and bolt. See Fig. 13 . Tighten the bolt/stud to specification. See
TORQUE SPECIFICATIONS .
6. Install the fuel feed/return and EVAP return pipe bracket nut. See Fig. 12 . Tighten the nut to
specification. See TORQUE SPECIFICATIONS .
7. Remove the plugs from the transmission oil cooler line fittings.
8. Connect the transmission oil cooler lines. See Fig. 11 . For additional information, see OIL COOLER
LINE QUICK CONNECT FITTING under REMOVAL & INSTALLATION in SERVICING AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E &
4L65-E) article.
9. Install the torque converter bolts. See Fig. 10 . Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
10. Install the bolt that secures the fuel line bracket to the left side of the transmission. See Fig. 9 . Tighten
the bolt to specification. See TORQUE SPECIFICATIONS .
11. Connect the VSS electrical connector (2). See Fig. 8 .
12. Connect the main electrical connector (1). See Fig. 8 .
13. Connect the PNP switch electrical connectors (2). See Fig. 7 .
14. Install the harness clip (1) to the fuel line bracket. See Fig. 7 .
15. Install the exhaust hanger bracket and bolts. See Fig. 6 . Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
16. Install the cable to the bracket.
17. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). See Fig. 5 .
19. Install the retainer that secures the cable to the bracket. See Fig. 4 .
20. Install the transmission mount and bolts. See Fig. 3 . Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
21. If equipped, install the transfer case. See appropriate REMOVAL & INSTALLATION article as follows:
z For Escalade, Escalade EXT, Yukon Denali and Yukon XL, see TRANSFER CASE ASSEMBLY
REPLACEMENT .
z See REMOVAL & INSTALLATION - SIERRA & SILVERADO article in TRANSFER
CASES.
z For Avalanche, Tahoe, Yukon & Yukon XL, see TRANSFER CASE ASSEMBLY
REPLACEMENT .
22. Install the starter motor. See appropriate STARTERS article in ELECTRICAL.
23. Install the exhaust pipe.
24. Raise the transmission slightly and install the transmission support. See Fig. 2 .
25. Install the transmission support bolts and nuts. Tighten the bolts and nuts to specification. See TORQUE
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26.
27.
28.
29.
30.
SPECIFICATIONS .
Install the transmission mount nuts. See Fig. 1 . Tighten the nuts to specification. See TORQUE
SPECIFICATIONS .
Remove the support from the transmission.
Install the rear driveshaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in
DRIVELINE/AXLES.
Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS .
Fill transmission with appropriate fluid to proper level. See LUBRICATION in SERVICING AVALANCHE, ESCALADE, SIERRA, SILVERADO, SUBURBAN, TAHOE & YUKON (4L60-E &
4L65-E) article.
TRANSMISSION MOUNT
Removal
1.
2.
3.
4.
5.
6.
7.
Raise and support the vehicle.

Support the transmission with a transmission jack.
Remove the transmission mount to the transmission support retaining nuts. See Fig. 1 .
Raise the transmission to take the weight off of the mount.
Remove the transmission mount to the transmission or transfer case adapter mounting bolts.
Raise the transmission just enough to remove the transmission mount.
Remove the transmission mount from the vehicle.
Installation
1. Install the transmission mount to the vehicle.

2. Install the transmission mount to the transmission or transfer case adapter mounting bolts. Tighten the
bolts to specification. See TORQUE SPECIFICATIONS .
3. Lower the transmission.
4. Install the transmission mount to the transmission support retaining nut or nuts. See Fig. 1 . Tighten the
nut or nuts to specification. See TORQUE SPECIFICATIONS .
5. Remove the transmission jack.
6. Lower the vehicle.
TORQUE SPECIFICATIONS
Application
EVAP Return Pipe Bracket Nut
Exhaust Hanger Bracket Bolts
Lower Right Transmission Stud & Bolt
Torque Converter Bolts
Ft. Lbs. (N.m)

15 (20)
13 (17)
37 (50)
46 (63)
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Transmission Mount Bolts

Transmission Mount Nuts
Transmission Mount-To-Transmission Or Transfer Case Adapter Mounting Bolts
Transmission Mount-To-Transmission Support Retaining Nuts
Transmission Studs & Bolt
Transmission Support Bolts & Nuts
Battery Cable Bolt
Fuel Line Bracket-To-Left Side Transmission Bolt
18 (25)
37 (50)
37 (50)
30 (40)
37 (50)
70 (95)
INCH Lbs. (N.m)
133 (15)
89 (10)
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2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Avalanche, Sierra, Silverado, Suburban & Yukon
(4L80-E & 4L85-E)

Removal & Installation - Avalanche, Sierra, Silverado, Suburban & Yukon (4L80-E & 4L85-E)
APPLICATION
Application
Chevrolet
Avalanche
Cab & Chassis, & Silverado
Silverado
Suburban
GMC
Cab & Chassis, & Sierra
Sierra
Yukon & Yukon XL
Transmission Model (RPO Code)

4L80-E (MT1) & 4L85-E (MN8)
4L80-E (MT1)
4L80-E (MT1)
4L80-E (MT1) & 4L85-E (MN8)
4L80-E (MT1)
4L80-E (MT1)
4L80-E (MT1) & 4L85-E (MN8)

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.
TRANSMISSION
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(4L80-E & 4L85-E)
Removal
1. Disconnect the negative (-) battery cable.

2. Drain the transmission fluid. See LUBRICATION in appropriate SERVICING article.
3. Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in
DRIVELINE/AXLES.
4. Support the transmission with a suitable jack.
5. Remove the transmission mount nuts. See Fig. 1 .
Fig. 1: Removing/Installing Transmission Support Bolts & Nuts

6.
7.
8.
9.
Remove the transmission support bolts and nuts. See Fig. 1 .

Raise the transmission slightly and remove the transmission support from the vehicle.
Remove the exhaust manifold pipe.
Remove the transfer case, if equipped. See appropriate REMOVAL & INSTALLATION article in
TRANSFER CASES.
10. Remove the transmission mount bolts and mount. See Fig. 2 .
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(4L80-E & 4L85-E)
Fig. 2: Removing/Installing Transmission Mount Bolts & Nuts

12. Remove the retainer that secures the cable to the bracket. See Fig. 3 .
13. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). See Fig.
4.
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(4L80-E & 4L85-E)
Fig. 3: Removing/Installing Range Selector Cable From Bracket

Courtesy of GM
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(4L80-E & 4L85-E)
Fig. 4: Identifying Range Selector Lever Ball Stud

Courtesy of GM
14. Depress the tangs and remove the cable from the bracket.
15. Disconnect the following electrical connectors:
z Input speed sensor (1). See Fig. 5 .
z Output speed sensor (3).
z Park/neutral position (PNP) switch (5).
z Transmission (4).
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(4L80-E & 4L85-E)
Fig. 5: Identifying Electrical Connectors

16.
17.
18.
19.
Disconnect the oxygen sensor (HO2S) electrical connector.

Disconnect the wire harness clip (2) from the bracket on the left side of the transmission.
Cut the tie strap to separate the vent hose from the wiring harness.
Remove the flywheel inspection cover. See Fig. 6 .
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(4L80-E & 4L85-E)
Fig. 6: Removing/Installing Flywheel Inspection Cover

20. Mark the torque converter to flywheel orientation.
21. Remove the torque converter bolts.
22. Remove the exhaust hanger mounting bracket bolts and brackets, if equipped. See Fig. 7 and Fig. 8 .
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(4L80-E & 4L85-E)
Fig. 7: Removing/Installing Exhaust Hanger Mounting Bracket (6.0L)

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(4L80-E & 4L85-E)
Fig. 8: Removing/Installing Exhaust Hanger Mounting Bracket (8.1L)

23.
24.
25.
26.
Disconnect the transmission oil cooler lines. See Fig. 9 .

Plug the transmission oil cooler line fittings.
Remove the stud on the left side of the transmission. See Fig. 10 .
Remove the remaining transmission studs. See Fig. 11 .
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(4L80-E & 4L85-E)
Fig. 9: Disconnecting Transmission Oil Cooler Lines

Courtesy of GM
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(4L80-E & 4L85-E)
Fig. 10: Removing/Installing Left Side Transmission Stud

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(4L80-E & 4L85-E)
Fig. 11: Removing/Installing Transmission Studs

Courtesy of GM
27. Install the Converter Holding Strap (J-21366) onto the transmission bell housing to retain the torque
converter.
28. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.
Pull the transmission straight back.
29. Remove the transmission from the vehicle.
Installation
1. Install the transmission to the vehicle.

2. Raise the transmission into place and remove the converter holding strap from the transmission.
3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the
torque converter. The torque converter must rotate freely by hand.
4. Install transmission studs and bolt. See Fig. 11 . Tighten the studs to specification. See TORQUE
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(4L80-E & 4L85-E)
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
SPECIFICATIONS .
Install the stud on the left side of the transmission. See Fig. 10 . Tighten the stud to specification. See
Remove the plugs from the transmission oil cooler line fittings. See Fig. 9 . Tighten the nut to
Connect the transmission oil cooler lines. Tighten to specification. See TORQUE SPECIFICATIONS .
If equipped, install the exhaust hanger mounting brackets and bolts. See Fig. 7 and Fig. 8 . Tighten the
bolts to specification. See TORQUE SPECIFICATIONS .
Align the torque converter to the flywheel.
Install the torque converter bolts. See Fig. 6 . Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
Install the flywheel inspection cover. Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
Connect the following electrical connectors:
z Input speed sensor (1). See Fig. 5 .
z Output speed sensor (3).
z PNP switch (5).
z Transmission (4).
Connect the HO2S electrical connector.
Connect the wire harness clip (2) to the bracket on the left side of the transmission.
Depress the tangs and install the cable to the bracket.
Install the range selector cable end (2) to the transmission range selector lever ball stud (1). See Fig. 4 .
Ensure the transmission manual shaft is positioned in mechanical park.
Install the retainer that secures the cable to the bracket. See Fig. 3 .
Install the transmission mount and bolts. See Fig. 2 . Tighten bolts to specification. See TORQUE
SPECIFICATIONS .
Install the transfer case, if equipped. See appropriate REMOVAL & INSTALLATION article in
TRANSFER CASES.
Install the exhaust manifold pipe. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
Install the transmission support. See Fig. 1 .
Install the transmission support bolts and nuts. Tighten the bolts and nuts to specification. See TORQUE
SPECIFICATIONS .
Install the transmission mount nuts. See Fig. 1 . Tighten the nuts to specification. See TORQUE
SPECIFICATIONS .
Remove the support from the transmission.
Install the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in
DRIVELINE/AXLES.
Connect the negative (-) battery cable.
Fill transmission with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING
article.
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(4L80-E & 4L85-E)
Application
Exhaust Manifold Pipe Nuts
Flywheel Inspection Cover
Heat Shield-To-Transmission Bolts
Oil Pan Drain Plug
Oxygen Sensor
PNP Switch Bolts
Range Selector Bracket Bolts
Transfer Case Adapter Nut
Transmission Studs
Transmission Support Bolts & Nuts
Ft. Lbs. (N.m)

39 (50)
24 (33)
13 (17)
13 (18)
31 (42)
18 (25)
18 (25)
44 (60)
37 (50)
18 (25)
37 (50)
37 (50)
75 (95)
INCH Lbs. (N.m)
133 (15)
106 (12)
Battery Cable Bolt

Exhaust Hanger Mounting Bracket Bolts
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Page 14

2002-03 AUTOMATIC TRANSMISSIONS A/T Removal & Installation - Sierra & Silverado (Allison LCT 1000)

A/T Removal & Installation - Sierra & Silverado (Allison LCT 1000)
APPLICATION
Application
Engine Size
Chevrolet
Cab & Chassis Silverado 3500, Silverado 2500 HD &
Silverado 3500
GMC
Cab & Chassis Sierra 3500, Sierra 2500 HD & Sierra
3500
Transmission Model (RPO

Code)
6.6L Or
8.1L
LCT 1000 (M74)
6.6L Or
8.1L
LCT 1000 (M74)

CAUTION: If 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
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Page 1

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.
TRANSMISSION
Removal (6.6L)
1.
2.
3.
4.
5.
Disconnect both of the negative (-) battery cables.

Remove the transmission fluid level indicator.
Raise the vehicle until the right front wheel and tire can be removed.
Remove the right front wheel and tire.
Remove the right front wheel house inner panel retainers (2). See Fig. 1 .
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Fig. 1: Locating Right Front Wheel House Inner Panel Retainers

6.
7.
8.
9.
10.
11.
Disconnect any harness retainers attached to the inner panel.

Remove the inner panel (2).
Remove the positive (+) battery cable nut and cable from the starter.
Remove the solenoid nut and wire from the starter. See Fig. 2 .
Remove the starter motor bolts and reposition the starter. See Fig. 3 .
Remove the engine protection shield bolts and shield. See Fig. 4 .
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Fig. 2: Removing/Installing Solenoid Nut & Wire From Starter

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Fig. 3: Removing/Installing Starter Motor Bolts

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Fig. 4: Removing/Installing Engine Protection Shield

CAUTION: Rotate the engine clockwise ONLY, rotating the engine
counterclockwise may loosen the crankshaft balancer bolt.
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. See Fig. 5 .
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Page 6


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).
See Fig. 6 .
17. Remove the shift cable bracket bolts and bracket (2) from the transmission. See Fig. 7 .
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Fig. 6: Disconnecting/Connecting Shift Cable From Selector Lever Ball Stud

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Page 8

Fig. 7: Identifying Bracket Bolts & Bracket From Transmission

18.
19.
20.
21.
22.
Reposition the bracket with the cable attached off to the side.
Remove the fuel line retainer (1) bolts on the left side of the transmission. See Fig. 8 .
Remove the fuel line bracket nut from the converter housing stud. See Fig. 9 .
Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. See Fig. 10 .
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. See Fig.
10 .
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Page 9

Fig. 8: Removing/Installing Fuel Line Retainer Bolts

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Page 10

Fig. 9: Removing/Installing Fuel Line Bracket Nut From Converter Housing Stud
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Page 11

Fig. 10: Identifying Speed Sensors & Electrical Connectors

23. Disconnect the transmission main electrical connector. The Connector Removal Tool (J-44257) may be
used, but is not required. See Fig. 11 .
24. Disconnect the Park/Neutral Position (PNP) switch electrical connector.
25. Remove the exhaust hanger bolts and reposition the hanger. See Fig. 12 .
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Fig. 11: Disconnecting/Connecting Transmission Main Electrical Connector

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Page 13

Fig. 12: Removing/Installing Exhaust Hanger Bolts

26. If the vehicle is a 2 wheel drive (2WD), remove the drive shaft. See appropriate DRIVE SHAFT &
UNIVERSAL JOINTS article in DRIVELINE/AXLES.
28. If the vehicle is a 2WD, remove the transmission mount nuts. See Fig. 13 .
29. If the vehicle is a 2WD, remove the transmission support bracket bolts. See Fig. 14 .
30. If the vehicle is a 2WD, remove the transmission support bolts and nuts. See Fig. 14 .
31. Remove the transmission mount bolts (1). See Fig. 15 .
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Fig. 13: Removing/Installing Transmission Mount Nuts (2WD)

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Page 15

Fig. 14: Removing/Installing Transmission Support Bracket Nuts & Bolts (2WD)
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Page 16

Fig. 15: Identifying Transmission Mount Bolts

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. See Fig. 16 .
36. Disconnect the transmission oil cooler lines (1 and 2) from the transmission. See Fig. 17 .
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Fig. 16: Securing Safety Chain Around Transmission

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Page 18

Fig. 17: Identifying Transmission Oil Cooler Lines

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. See Fig. 18 .
40. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the
bracket. See Fig. 19 .
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Fig. 18: Removing/Installing Transmission Fill Tube Nuts

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Page 20

Fig. 19: Removing/Installing Wire Harness & Vent Tube Bracket Nut
41. Remove the remaining converter housing bolts and studs. See Fig. 20 .
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. See Fig. 21 .
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Fig. 20: Removing/Installing Converter Housing Bolts & Studs

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Page 22

Fig. 21: Installing Converter Holding Strap

44. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
Installation (6.6L)
1. Install converter holding strap to the converter housing in order to keep the torque converter from sliding
off of the turbine shaft. See Fig. 21 .
2. Raise the transmission into place while simultaneously installing the transmission fill tube.
CAUTION: Do not install the transmission by drawing it to the engine using the
studs and bolts.
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Page 23

4. Align the transmission with the engine using the alignment dowels located at the rear of the engine. See
Fig. 20 .
CAUTION: Ensure that the torque converter can be rotated before tightening the
bolts and studs.
5. Install the converter housing bolts and studs. Tighten the bolts and studs to specification. See TORQUE
SPECIFICATIONS .
6. Install the wire harness/vent tube bracket and nut to the converter housing stud. See Fig. 19 . Tighten the
nut to specification. See TORQUE SPECIFICATIONS .
7. Install the transmission fill tube and nuts to the converter housing studs. See Fig. 18 . Tighten the nuts to
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. See Fig. 16 .
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). See Fig. 15 . Tighten the bolts to
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. See Fig. 14 . Tighten the bolts/nuts
to specification. See TORQUE SPECIFICATIONS .
16. If the vehicle is a 2WD, install the transmission mount nuts. See Fig. 13 . Tighten the nuts specification.
See TORQUE SPECIFICATIONS .
17. If the vehicle is a 2WD, install the transmission mount nuts. Tighten the nuts to specification. See
18. If the vehicle is a 2WD, install the drive shaft.
19. Position the exhaust hanger and install the bolts. See Fig. 12 . Tighten the bolts to specification. See
20. Position the wiring harness branches.
21. Connect the PNP switch electrical connectors.
22. Connect the transmission main electrical connector (2). See Fig. 22 .
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Fig. 22: Connecting Transmission Main Electrical Connector

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.
See Fig. 10 .
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. See Fig. 9 . Tighten the
nut to specification. See TORQUE SPECIFICATIONS .
26. Install the fuel line retainer (1) and bolts to the left side of the transmission. See Fig. 8 . Tighten the bolts
to specification. See TORQUE SPECIFICATIONS .
27. Install the shift cable bracket (2) and bolts to the transmission. See Fig. 7 . Tighten the bolts to
28. Install the shift cable to the bracket (3) and the selector lever ball stud (5). See Fig. 6 .
29. Remove the access hole cover (1) on the converter housing in order to rotate the converter and align the
first torque converter bolt. See Fig. 23 .
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Fig. 23: Removing Access Hole Cover

30. Install the torque converter bolts. See Fig. 5 . Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
31. Install the converter housing access hole cover.
32. Install the engine protection shield and bolts. See Fig. 4 . Tighten the bolts to specification. See
33. Position and install the starter motor bolts. See appropriate STARTERS article in ELECTRICAL. See
Fig. 3 . Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
34. Install the solenoid wire and nut to the starter. See Fig. 2 . Tighten the nut to specification. See TORQUE
SPECIFICATIONS .
35. Install the positive battery cable and nut to the starter. Tighten the nut to specification. See TORQUE
SPECIFICATIONS .
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Page 26

36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
Install the inner panel (2).

Connect any harness retainers to the inner panel.
Install the right front wheel house inner panel retainers (2). See Fig. 1 .
Install the right front wheel and tire.
Remove the plugs from the transmission oil cooler line fittings in the transmission case, if necessary.
Flush the transmission oil cooler and lines, if necessary.
Connect the transmission oil cooler lines (1 and 2) to the transmission. See Fig. 17 .
Lower the vehicle.
Connect both negative (-) battery cables.
Fill the transmission with new transmission fluid.
Install the transmission fluid level indicator.
If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. See
PROGRAMMING in appropriate DIAGNOSIS article.
Removal (8.1L)
1.
2.
3.
4.
5.
Disconnect the negative (-) battery cable.

Remove the transmission fluid level indicator.
Raise and suitably support the vehicle.
Remove the engine protection shield bolts and shield. See Fig. 4 .
Remove the starter motor bolts and position the starter motor aside. See Fig. 24 .
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Page 27

Fig. 24: Removing/Installing Starter Motor & Bolts

6. Drain the transmission fluid, if necessary.
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Page 28

7. If the vehicle is a 2 wheel drive (2WD), remove the drive shaft. See appropriate DRIVE SHAFTS &
UNIVERSAL JOINT article in DRIVELINE/AXLES.
9. If the vehicle is a 2WD, remove the transmission mount nuts. See Fig. 13 .
10. If the vehicle is a 2WD, remove the transmission support bracket bolts. See Fig. 14 .
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). See Fig. 15 .
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).
See Fig. 6 .
17. Remove the shift cable bracket bolts and bracket (2) from the transmission. See Fig. 7 .
18. Disconnect the turbine speed sensor (1) and input speed sensor (2) electrical connectors. See Fig. 10 .
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. See Fig. 11 .
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. See Fig. 8 .
23. Remove the transmission heat shield bolt and nut (4 and 5) and shield (3). See Fig. 25 .
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Page 29

Fig. 25: Removing Transmission Heat Shield Bolt & Nut

24. Remove the exhaust pipe hanger bolts and reposition the hanger. See Fig. 12 .
25. Remove the transmission heat shield bolts (2) and shield (1). See Fig. 25 .
26. Remove the converter housing inspection cover bolts and cover. See Fig. 26 .
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Page 30

Fig. 26: Removing Converter Housing Inspection Cover Bolts & Cover
through the starter opening. Have an assistant rotate the engine while aligning the bolts.
28. Remove the torque converter bolts (3). See Fig. 27 .
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Page 31


29. Remove the transmission fill tube nuts from the converter housing studs. See Fig. 18 .
30. Remove the fuel line bracket nut from the converter housing stud. See Fig. 9 .
31. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the
bracket. See Fig. 19 .
32. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other
related components. See Fig. 16 .
33. Disconnect the transmission oil cooler lines (1 and 2) from the transmission. See Fig. 17 .
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. See Fig. 28 .
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Page 32

Fig. 28: Identifying Converter Housing Bolts & Studs

37. Separate the transmission from the engine.
39. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
Installation (8.1L)
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Page 33

2. Raise the transmission into place while simultaneously installing the fill tube.
CAUTION: Do not install the transmission by drawing it to the engine using the
studs and bolts.
4. Align the transmission with the engine using the alignment dowels located at the rear of the engine.
5. Install the converter housing bolts and studs. See Fig. 28 . Tighten the bolts/studs to specification. See
6. Position the wire harness/vent tube bracket and install the wire harness/vent tube bracket nut to the
converter housing stud. See Fig. 19 . Tighten the nut to specification. See TORQUE
SPECIFICATIONS .
7. Install the fuel line bracket nut to the converter housing stud. See Fig. 9 . Tighten the nut to specification.
8. Install the transmission fill tube nuts to the converter housing studs. See Fig. 18 . Tighten the nuts to
9. Remove the safety chain from around the transmission. See Fig. 16 .
through the starter opening. Have an assistant rotate the engine while aligning the bolts. See Fig. 27 .
11. Install the torque converter bolts (3). Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
12. Install the converter housing inspection cover and bolts. See Fig. 26 . Tighten the bolts to specification.
13. Install the transmission heat shield (1) and bolts (2). See Fig. 25 . Tighten the bolts to specification. See
14. Position the hanger and install the exhaust pipe hanger bolts. See Fig. 14 . Tighten the bolts to
15. Install the transmission heat shield (3) and bolt/nut (4 and 5). See Fig. 25 . Tighten the bolt/nut to
16. Install the fuel line retainer (1) bolts to the left side of the transmission. See Fig. 8 . Tighten the bolts to
17. Connect the PNP switch electrical connector.
18. Disconnect the transmission main electrical connector (2). See Fig. 22 .
19. 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 will be disconnected later. See Fig. 10 .
20. Connect the turbine speed sensor (1) and input speed sensor (2) electrical connectors.
21. Install the shift cable bracket (2) and bolts to the transmission. See Fig. 7 . Tighten the bolts to
22. Connect the shift cable to the selector lever ball stud (5) and install the cable to the bracket (3). Connect
the shift cable to the selector lever ball stud (5) and install the cable to the bracket (3). See Fig. 6 .
23. Install the transmission mount.
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Page 34

24. Install the transmission mount bolts (1). See Fig. 17 . Tighten the bolts to specification. See TORQUE
SPECIFICATIONS .
25. If the vehicle is equipped with 4WD, install the transfer case. See appropriate REMOVAL &
INSTALLATION article in TRANSFER CASES.
26. If the vehicle is a 2WD, install the transmission support. See Fig. 14 .
27. If the vehicle is a 2WD, install the transmission support bolts and nuts.
28. If the vehicle is a 2WD, install the transmission support bracket bolts. Tighten the bolts/nuts to
29. If the vehicle is a 2WD, install the transmission mount nuts. See Fig. 13 . Tighten the nuts to
30. Remove the transmission jack from the transmission.
31. If the vehicle is a 2WD, install the drive shaft.
32. Position the starter motor and install the starter motor bolts. See Fig. 24 . Tighten the bolts to
33. Install the engine protection shield and bolts. See Fig. 4 . Tighten the bolts to specification. See
34. If the vehicle is equipped with a PTO unit, connect and/or install any necessary components.
35. Remove the plugs from the transmission oil cooler line fittings in the transmission case.
36. Flush the transmission oil cooler and lines, if necessary. See OIL COOLER FLUSHING under
LUBRICATION in appropriate SERVICING article.
37. Connect the transmission oil cooler lines (1 and 2) to the transmission. See Fig. 17 .
38. Lower the vehicle.
39. Connect the negative (-) battery cable. Tighten bolt to specification. See TORQUE
SPECIFICATIONS .
40. Fill transmission with appropriate fluid to proper level. See LUBRICATION in appropriate SERVICING
article.
41. Install the transmission fluid level indicator.
42. If a replacement transmission was installed, perform the "FastLearn" procedure using a scan tool. See
PROGRAMMING in appropriate DIAGNOSIS article.
Application
Battery Cable (Negative)
Converter Housing Bolts & Stud
Engine Protection Shield & Bolt
Fuel Line Bracket Nut
Fill Tube Nut-To-Converter Housing Stud
Shift Cable Bracket Bolts
Ft. Lbs. (N.m)

13 (17)
37 (50)
15 (20)
13 (18)
13 (18)
18 (25)
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Page 35

Starter Motor Bolts

6.6L
8.1L
Transmission Heat Shield Bolts
Transmission Support Bracket Bolts
Wire Harness/Vent Tube Bracket
58 (78)
37 (50)
44 (60)
13 (17)
37 (50)
30 (40)
70 (95)
13 (18)
INCH Lbs. (N.m)
80 (9)
89 (10)
106 (12)
22 (2.5)
30 (3.4)
Battery Positive Cable-To-Starter

Converter Housing Inspection Cover Bolt
Exhaust Hanger Pipe
Fuel Line Retainer Bolts
Wire-To-Starter Solenoid Nut
Helpmelearn
April-29-08 6:56:29 PM
Page 36

At Removal &amp; Installation

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2003 Chevrolet Silverado 1500

2002-03 AUTOMATIC TRANSMISSIONS

Transmission Model (RPO Code)

REMOVAL & INSTALLATION

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

GENERAL INFORMATION before disconnecting battery.

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 1: Removing/Installing Transmission Mount Nuts

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 2: Removing/Installing Transmission Support Bolts & Nuts

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 3: Removing/Installing Transmission Bolts & Mount

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 4: Removing/Installing Cable-To-Bracket Retainer

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 5: Disconnecting Range Selector Cable

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 6: Removing/Installing Exhaust Hanger Bracket

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 7: Identifying Harness Clip & PNP Switch

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 8: Identifying Main Electrical Connector & VSS

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 9: Removing/Installing Fuel Line Bracket-To-Left Side Transmission Bolt

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 10: Identifying Torque Converter Bolts

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 11: Disconnecting Transmission Oil Cooler Lines

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 12: Removing/Installing EVAP Return Pipe Bracket Nut

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 13: Removing Lower Right Transmission Bolt & Stud

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Fig. 14: Removing/Installing Remaining Transmission Studs & Bolts

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Raise and support the vehicle.

1. Install the transmission mount to the vehicle.

Ft. Lbs. (N.m)

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

Transmission Mount Bolts

2005 Mitchell Repair Information Company, LLC.

2003 Chevrolet Silverado 1500

2002-03 AUTOMATIC TRANSMISSIONS

Transmission Model (RPO Code)

REMOVAL & INSTALLATION

At Removal & Installation

At Removal & Installation