Chevrolet 24252997 Transmission Assembly, Man

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The removal of the transmission includes the removal of the driveline consisting of the transmission, differential and the driveshaft housing as a single unit, after then the differential and the driveshaft housing has to be separated from the transmission. Particular attention should be paid to the gap between the rear of the engine and the firewall when lowering the rear part of the driveline for removal with the engine in place it must not touch the firewall. First remove the ground cable, unbolt the rear wheel lug nuts and then securely jack up the car at both ends placing it on jackstand. Within the automobile, take off the shift control assembly and the clutch master cylinder linkage detached from the clutch. On models up to year 2004, the procedure involves the removal of the clutch fluid pressure line from the clip at the rear of the engine then detaching it from the clutch master hydraulic line. In those vehicles produced from 2005 and with later model year, detach the clutch fluid pressure line with the help of a certain clip. The rear wheels should be detached subsequently and the transmission shifted to neutral while the intermediate exhaust pipe should be detached while moving the mufflers away from the differential. On models from 1998 and earlier with aEBT module mounted on the rear top side of the subframe: uninstall left mounting bracket bolts and remove bracket. Remove the outer tie-rod end from the knuckle and separate the lower control arm from its shock absorber, and 'unbolt' the rear knuckle ball joint to the lower control arm ball joint on the other side. It is then necessary to disconnect the wiring harness or hydraulic line retainer, if any, on the subframe, and then pull off the nut that is at the bottom of the transmission-differential link and the nut(s) that holds the transmission mount to the subframe-With the 2004 and earlier models having only single transmission mount as compared to the 2005 and later models having twin transmission mounts. Isolate and support the rear subframe in a manner that will allow for easy removal of the subframe while maintaining the transmission/differential still inside the vehicle. Lower the rear subframe using only hand tools, unscrew the nuts that hold the rear subframe in place. When towing pre 2004 models, the transmission mount needs to be removed, as do the brackets from the differential to protect the studs. Remove the drive axles from the differential and fasten them; pull the vehicle speed sensor connector wiring. Lower the driveline slightly and unplug the wiring harness clips from the driveshaft housing, so that none of the retainer and connectors will interfere with the process of removing the said component. Place an engine hoist under the back of the oil pan to support it from tipping forward, then impact the 5 bolts that hold the driveshaft housing to the bellhousing and, 'smart' the harness bracket to ease its removal. Gradually twist the driveshaft housing from side to side until it comes loose from the bellhousing; and tilt the driveline at the same time if there is need to do so. Carry on lowering the driveline till it comes to a point where it can be taken out from under the car. If necessary, take off the differential from the transmission, take off the driveshaft housing from the transmission, using a punch or a drift knock out the roll pin on the shift lever. For installation, bolt the driveshaft housing to the transmission and well torque the fasteners while getting the differential in place and well secured. On the shift rod ensure you fix a rubber band to enhance the installation process and fix the other end of the rubber band onto the driveshaft housing so that it may not shift from its position. With the driveline raised towards the position put a plastic putty knife between the shift bracket and brake line retaining clips and lubricate the input shaft with a light coat of high temperature grease. Lift the driveline into position in line with the engine and with considerable care engage the splined end of the input shaft with the clutch hub without undue force. Place the harness in position where the housing has been raised and lock the driveline in position by making the driveshaft housing fit perfectly over the engine before the use of bolts to secure the harness. The rest of the remaining installation is done in the reversed order to its removal, of course with extra attentiveness to the harness and the connectors of the sensors before lifting the driveline, then installing and tightening the bolts of the rear cross member, then Finally replacing the transmission fluid, and finally bleeding the clutch system. Finally, turn further upwards the shift rod which pulls the masking tape and stretches the rubber band over the shifter boot stud, and finally lower the car and operate check.

Problems with the automatic transmission should be assessed by a dealer service department or other qualified repair facility.

Overhauling a manual transmission involves the disassembly and reassembly of numerous small parts, requiring precise measurements of clearances that may need adjustment using select-fit spacers and snap-rings.

Support the transmission and rear subframe separately to lower and remove the rear subframe while keeping the transmission/differential assembly in the vehicle.