GM Service Manual Online
For 1990-2009 cars only

Removal Procedure


    Object Number: 834241  Size: SH
  1. If equipped with all wheel drive (AWD), 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
  4. If equipped with AWD, remove the differential carrier lower mounting bolt and nut.

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

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

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

  13. Object Number: 832978  Size: SH
  14. Remove the transmission cover bolt and cover.
  15. Drain the engine oil and remove the engine oil filter.
  16. Re-install the drain plug and oil filter until snug.

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

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

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

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

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

  28. Object Number: 310672  Size: SH
  29. Remove the positive battery cable clip bolt.

  30. Object Number: 683355  Size: SH
  31. Remove the oil pan bolts.
  32. Remove the oil pan.

  33. 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.

  34. Drill (3) out the oil pan gasket retaining rivets (2), if required.
  35. Remove the gasket (1) from the pan.
  36. Discard the gasket and rivets.
  37. If required, clean and inspect the engine oil pan. Refer to Oil Pan Cleaning and Inspection .

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 20 mm (0.80 in) long to the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number. 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
  3. Apply a 5 mm (0.20  in) bead of sealant 20 mm (0.8 in) long to the engine block. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number. Apply the sealant directly onto the tabs of the rear cover gasket that protrudes into the oil pan surface.

  4. 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.

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

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

  11. Object Number: 394448  Size: SH
  12. Install the transmission bolt and stud on the right side until snug, If equipped with the 4L60-E automatic transmission.
  13. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 394446  Size: SH
  14. Install the bottom bolt on the left side until snug.
  15. 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
  16. Install the positive battery cable clip bolt.
  17. Tighten
    Tighten the bolt to 9 N·m (80 lb in).


    Object Number: 662508  Size: SH
  18. Slide the channel pin into the oil pan tab.
  19. Install the battery cable channel bolt.
  20. Tighten
    Tighten the bolt to 12 N·m (106 lb in).


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

  22. Object Number: 832978  Size: SH
  23. Install the transmission cover and bolt.
  24. Tighten
    Tighten the bolt to 12 N·m (106 lb in).


    Object Number: 328107  Size: SH
  25. Install the crossbar.
  26. Install the crossbar bolts.
  27. Tighten
    Tighten the bolts to 100 N·m (74 lb ft).


    Object Number: 663487  Size: SH
  28. Install the transmission cover bolt.
  29. Tighten
    Tighten the bolt to 12 N·m (106 lb in).


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

  32. Object Number: 834278  Size: SH
  33. If equipped with AWD, install the differential carrier lower mounting bolt and nut.
  34. Tighten
    Tighten the bolts to 100 N·m (75 lb ft).


    Object Number: 834241  Size: SH
  35. If equipped with AWD, install the inner axle housing washers and nuts to the bracket.
  36. Tighten
    Tighten the nuts to 100 N·m (75 lb ft).

  37. Remove the jack from the front drive axle.
  38. Install new engine oil and a new oil filter. Refer to Engine Oil and Oil Filter Replacement .