GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Avalanche - 4WD 🢒 Engine 🢒 Engine Mechanical - 4.8L, 5.3L, and 6.0L 🢒 Oil Pan Replacement

Removal Procedure

    Object Number: 834241 Size: SH
  1. If equipped with four wheel drive (4WD), remove the inner axle housing nuts and washers from the bracket.
  2. Support the front drive axle with a suitable jack.

    3. Object Number: 834278 Size: SH
  3. If equipped, with 4WD, remove the differential carrier lower mounting bolt and nut.

    4. Object Number: 834276 Size: SH
  4. If equipped with 4WD, remove the differential carrier upper mounting bolt and nut.
  5. Lower the front drive axle.

    6. Object Number: 663487 Size: SH
  6. Remove the transmission cover bolt.

    7. Object Number: 309158 Size: SH
  7. If equipped, remove the oil pan skid plate bolts.
  8. Remove the oil pan skid plate.

    9. Object Number: 328107 Size: SH
  9. Remove the crossbar bolts.
  10. Remove the crossbar.

    11. Object Number: 178477 Size: SH
  11. Remove the transmission cover bolt and cover.
  12. Drain the engine oil and remove the engine oil filter.
  13. Re-install the drain plug and oil filter until snug.

    14. Object Number: 394448 Size: SH
  14. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.

    15. Object Number: 394446 Size: SH
  15. Remove the bottom bolt on the left side.

    16. Object Number: 396795 Size: SH
  16. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.

    17. Object Number: 662991 Size: SH
  17. Disconnect the oil level sensor electrical connector (6).

    18. Object Number: 662508 Size: SH
  18. Remove the battery cable channel bolt.
  19. Slide the channel pin out of the oil pan tab.

    20. Object Number: 310672 Size: SH
  20. Remove the positive battery cable clip bolt and clip.

    21. Object Number: 683355 Size: SH
  21. Remove the oil pan bolts.
  22. Remove the oil pan.

    23. Object Number: 384699 Size: SH

    Important: DO NOT allow foreign material to enter the oil passages of the oil pan, cap or cover the openings as required.

  23. Drill (3) out the oil pan gasket retaining rivets (2), if required.
  24. Remove the gasket (1) from the pan.
  25. Discard the gasket and rivets.
  26. Clean and inspect the engine oil pan. Refer to Oil Pan Cleaning and Inspection in Engine Mechanical - 4.8L, 5.3L, and 6.0L Unit Repair.

Installation Procedure

Important: 

   • The alignment of the structural oil pan is critical. The rear bolt hole locations of the oil pan provide mounting points for the transmission bellhousing. To ensure the rigidity of the powertrain and correct transmission alignment, it is important that the rear of the block and the rear of the oil pan must NEVER protrude beyond the engine block and transmission bellhousing plane.
   • Do not reuse the oil pan gasket.
   • It is not necessary to rivet the NEW gasket to the oil pan.


    Object Number: 451897 Size: SH
  1. Apply a 5 mm (0.20 in) bead of sealant GM P/N United states 12378190, or equivalent 20 mm (0.80 in) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface.

    2. Object Number: 451898 Size: SH
  2. Apply a 5 mm (0.20  in) bead of sealant GM P/N United States 12378190, or equivalent 20 mm (0.8 in) long to the engine block. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.

    3. Object Number: 683355 Size: SH

    Important: Be sure to align the oil gallery passages in the oil pan and engine block properly with the oil pan gasket.

  3. Pre-assemble the oil pan gasket to the pan.
    4. • Install the gasket onto the pan.
    • Install the oil pan bolts to the pan and through the gasket.
  4. Install the oil pan, gasket and bolts to the engine block.
  5. Tighten the oil pan bolts until snug. Do not overtighten.

    6. Object Number: 396795 Size: SH
  6. Install the transmission converter cover bolts until snug, if equipped with the 4L80-E automatic transmission.

    7. Object Number: 394448 Size: SH
  7. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission.

    8. Object Number: 394446 Size: SH

    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.

  8. Install the bottom bolt on the left side until snug.

    9. Tighten

    1. Tighten the oil pan-to-front cover bolts to 25 N·m (18 lb ft).
    2. Tighten the oil pan-to-rear cover bolts to 12 N·m (106 lb in).
    3. Tighten the converter cover, and transmission bolts/stud to 50 N·m (37 lb ft).

    Object Number: 310672 Size: SH
  9. Install the positive battery cable clip and bolt to the oil pan.

    10. Tighten
    Tighten the positive battery cable clip bolt to 9 N·m (80 lb in).


    Object Number: 662508 Size: SH
  10. Slide the channel pin in to the oil pan tab.
  11. Install the battery cable channel bolt.

    12. Tighten
    Tighten the battery cable channel bolt to 12 N·m (106 lb in).


    Object Number: 662991 Size: SH
  12. Connect the oil level sensor electrical connector (6).

    13. Object Number: 178477 Size: SH
  13. Install the transmission cover and bolt.

    14. Tighten
    Tighten the transmission cover bolt to 12 N·m (106 lb in).


    Object Number: 328107 Size: SH
  14. Install the crossbar.
  15. Install the crossbar bolts.

    16. Tighten
    Tighten the crossbar bolts to 100 N·m (74 lb ft).


    Object Number: 309158 Size: SH
  16. If equipped, install the oil pan skid plate.
  17. Install the oil pan skid plate bolts.

    18. Tighten
    Tighten the oil pan skid plate bolts to 20 N·m (15 lb ft).


    Object Number: 663487 Size: SH
  18. Install the transmission cover bolt.

    19. Tighten
    Tighten the transmission cover bolt to 12 N·m (106 lb in).


    Object Number: 834276 Size: SH
  19. Raise the front drive axle into position.
  20. If equipped with 4WD, install the differential carrier upper mounting bolt and nut until snug. Do not tighten at this time.

    21. Object Number: 834278 Size: SH
  21. If equipped, with 4WD, install the differential carrier lower mounting bolt and nut.

    22. Tighten
    Tighten the bolts to 100 N·m (75 lb ft).


    Object Number: 834241 Size: SH
  22. If equipped with 4WD, install the inner axle housing nuts and washers to the bracket.

    23. Tighten
    Tighten the nuts to 100 N·m (75 lb ft).

  23. Remove the front drive axle support.
  24. Install new engine oil and a new oil filter. Refer to Engine Oil and Oil Filter Replacement .