Automatic Transmission Servicing (4l60-e) Chevrolet Chevy Express H2500

APPLICATION

TRANSMISSION APPLICATION

OIL PAN GASKET

Note. For transmission oil pan gasket identification (Scheme 85)

Scheme 85

SERVICE INTERVALS

Check transmission fluid level at each engine oil change. At 50,000 miles, change the automatic transmission fluid and the filter if the vehicle's GVWR exceeds 8600 lbs. or if the vehicle is mainly driven under heavy city traffic where the outside temperature regularly reaches 90°F (32°C) or higher, in hilly or mountainous terrain, when frequently towing a trailer or used as a taxi, police or delivery service vehicle. If the vehicle is not used under any of these conditions, change the fluid and filter at 100,000 miles.

Checking Fluid Level

1. Start the engine and operate the vehicle for 15 minutes or until the transmission fluid reaches an operating temperature of 180-200°F (82-93°C).
2. Park the vehicle on a level surface.
3. With your foot on the brake, move the shift lever through each gear range. Pause for about 3 seconds in each range, ending in Park.
4. Apply the parking brake and let the engine idle for 3 minutes.
5. Remove the transmission fluid level indicator. Wipe the indicator clean. Insert the indicator. Give the indicator a full twist in order to close.
6. Wait 3 seconds and remove the indicator.
7. Read both sides of the indicator. The fluid must be within the hot cross-hatched area using the lowest level reading.

Checking Fluid Condition

1. Check the fluid color. Is the fluid Red in color? If so, go to step 5 . If not, go to next step.
2. Is the fluid a non-transparent Pink in color? If so, go to step 14 . If not, go to next step. NOTE: Fluid may turn a Dark Brown in color from normal use. This does not always indicate an oxidation or a contamination issue.
3. Is the fluid a Light Brown in color? If so, go to step 5 . If not, go to next step.
4. Is the fluid Black in color and or have a burnt smell? If so, go to step 14 . If not, go to next step.
5. Does the fluid appear as a solid liquid and not foamy or full of bubbles on level indicator? If so, go to next step. If not, go to step 7 .
6. Check the fluid level. Proper level should be in middle of the "X" pattern, on level indicator. Is the level okay? If so, go to step 19 . If not, go to next step.
7. Is the fluid level high on indicator? If so, go to step 12 . If not, go to next step.
8. Is the fluid level low on indicator? If so, go to next step. If not, go to step 4 .
9. Check for any external leak or leaks. Did you find an external leak or leaks? If so, go to next step. If not, go to step 11 .
10. Correct leak or leaks as needed. Are any leak or leaks still present? If so, go to step 9 . If not, go to next step.
11. Add fluid until level is in middle of "X" pattern on the level indicator. Is the level okay? If so, go to step 19 . If not, go to step 6 .
12. Drain fluid until level is in middle of "X" pattern on the level indicator. Is level okay? If so, go to step 19 . If not, go to step 6 .
13. Replace oil cooler and flush lines. See «AUXILIARY OIL COOLER»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e) under REMOVAL & INSTALLATION. Is the replacement complete? If so, go to step 15 . NOTE: A small amount of friction material in pan bottom is a normal condition, but large pieces and or metal particles will require complete transmission overhaul.
14. Drain fluid and remove oil pan to inspect. Is there sign or signs of internal component damage noted in bottom of transmission oil pan? If so, go to step 16 . If not go to step 13 .
15. Replace the filter and fluid. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) . Is the replacement complete? If so, go to step 6 .
16. Flush oil cooler and lines and check flow. See «OIL COOLER FLUSHING & FLOW CHECK»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__oil-cooler-flushing-flow-check) . Is the oil cooler flushing and flow test complete? If so, go to step 17 .
17. Overhaul transmission. See appropriate OVERHAUL article. Is the overhaul procedure complete? If so, go to next step.
18. Add new fluid. Is the procedure complete? If so, go to step 6 .
19. Check the fluid level and correct as necessary. Is the fluid level satisfactory? If so, system is okay. If not, go to step 1 .

RECOMMENDED FLUIDS

Manufacturer recommends Dexron(R)-III ATF.

FLUID CAPACITIES

The following refill capacities given are approximate. Correct fluid level should always be determined by marks on dipstick, rather than amount of fluid added. DO NOT overfill. See TRANSMISSION FLUID CAPACITIES table.

TRANSMISSION FLUID CAPACITIES

DRAINING & REFILLING

Note. Transmission may be equipped with a reusable oil pan gasket. Reusable oil pan gaskets are constructed of rubber with metal or plastic backing. On transmissions equipped with a reusable gasket, sealing surface of oil pan is flat. Transmissions not equipped with reusable-type gasket have a ridge on sealing surface of oil pan, and must have a new gasket every time pan is removed. Clean reusable gasket with solvent. Inspect reusable gasket for damage and replace as necessary. Using any other type of gasket in place of reusable gasket may result in fluid leaks.

1. Raise and support the vehicle. Place a drain pan under the transmission oil pan. Remove the oil pan drain plug, if equipped. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket.
2. Remove the oil pan bolts from the front and sides of the pan only. Loosen the rear oil pan bolts approximately 4 turns. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain.
3. Remove the remaining oil pan bolts. Remove the oil pan and the gasket. Grasp firmly while pulling down with a twisting motion in order to remove the filter. Remove the filter seal. (Scheme 86) The filter seal may be stuck in the pump. If necessary, carefully use pliers or another suitable tool to remove the seal. Discard the seal.
4. Inspect the fluid color. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: Clutch material. Bronze slivers indicating bushing wear. Steel particles.
5. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material, unless it equipped with a reusable rubber gasket. Clean rubber gasket with solvent and air dry.
6. To reassemble, coat the new filter seal with automatic transmission fluid. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket. Install the new filter into the case. Install the oil pan and a new gasket, if needed.
7. Install the oil pan bolts. Tighten the oil pan to transmission case bolts alternately and evenly to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
8. If previously removed, install the range selector cable bracket and bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
9. Apply a small amount of sealant (GM P/N 12346004) to the threads of the oil pan drain plug, if equipped. Install the oil pan drain plug, if equipped. Tighten the oil pan drain plug to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
10. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities). Check the COLD fluid level reading for initial fill only. Inspect the oil pan gasket for leaks.

Scheme 86

OIL COOLER FLUSHING & FLOW CHECK

Note. Tools required: Transmission Oil Cooler Flusher (J-35944-A), Transmission Oil Cooler Flushing Fluid (J-35944-22), Cooler Flushing Adapter (J-35944-200), measuring cup, funnel, water supply (hot water recommended), water hose with at least 5/8" (16 mm) ID, shop air supply (with water/oil filters, regulator and pressure gage), air chuck (with clip, if available), oil drain container, pail with lid (5 gallon), eye protection and rubber gloves.

Preparation

1. During the installation of the repaired or replacement transmission, DO NOT connect the oil cooler pipes.
2. Remove the fill cap (9) on the transmission oil cooler line flusher and fill the flusher tank (4) with 20-21 oz. (0.6L) of flushing solution using the measuring cup (6). (Scheme 87) DO NOT overfill.
3. Install the fill cap (9) on the flusher and pressurize the flusher tank (4) to 80-100 psi (550-700 kPa), using the shop air supply at the tank air valve (2).
4. With the water supply valve (1) on the flusher in the OFF position, connect the water supply hose (7) from the flusher to the water supply at the faucet.
5. Turn ON the water supply at the faucet.

Scheme 87

Back Flush

1. Inspect the transmission oil cooler pipes for kinks or damage. Repair as necessary.
2. Connect the transmission oil cooler flusher to the oil cooler feed bottom connector. Use the cooler flushing adapter, if required.
3. Clip the discharge hose (5) onto the oil drain container. (Scheme 88)
4. Attach the flusher to the undercarriage of the vehicle with the hook provided and connect the flushing system feed supply hose (3) from the flusher to the top connector oil cooler return pipe. Use the cooler flushing adapter, if required.
5. Turn the flusher water supply valve (1) to the ON position and allow water to flow through the oil cooler and pipes for 10 seconds to remove any remaining transmission fluid. If water does not flow through the oil cooler and pipes, the cause of the blockage must be diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing and flow check procedure once the blockage is corrected.
6. Turn the flusher water supply valve (1) to the OFF position and clip the discharge hose (5) onto an appropriate container with a lid, to avoid splashback. NOTE: Flushing for approximately 2 minutes in each cooler line direction will result in a total of about 8-10 gallons of waste fluid. This mixture of water and flushing fluid is to be captured in an appropriate container for proper disposal.
7. Turn the flusher water supply valve (1) to the ON position and depress the trigger (8) to mix cooler flushing solution into the water flow. Use the clip provided on the handle to hold the trigger (8) down. (Scheme 89) The discharge will foam vigorously when the solution is introduced into the water stream.
8. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air supply of 120 psi (825 kPa) to the flushing system feed air valve (2) located on the flusher for 3-5 seconds at the end of every 15-20 second interval to create a surging action.
9. Release the trigger (8) and turn the flusher water supply valve (1) to the OFF position.

Scheme 88

Scheme 89

Forward Flush

1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. (Scheme 88) This will allow the oil cooler and pipes to be flushed in the normal flow direction.
2. Repeat steps 6 - 8 of the INITIAL FLUSH procedure.
3. Release the trigger (8) of the flusher and allow water only to rinse the oil cooler and pipes for one minute. (Scheme 89)
4. Turn the flusher water supply valve (1) to the OFF position and turn OFF the water supply at the faucet.
5. Attach the shop air supply to the flushing system feed air valve (2) on the flusher, and blow out the water from the oil cooler and pipes. Continue until no water comes out of the discharge hose (5).

Flow Check

Note. The Flow Test must be performed after the flush to ensure that all flushing solution and water is removed from the oil cooling system.

1. Disconnect the hose from the oil cooler pipe. Connect the oil cooler feed pipe, bottom connector, to the transmission for normal flow.
2. Clip the discharge hose (5) onto the empty oil drain container. (Scheme 90)
3. Confirm the transmission is filled with automatic transmission fluid. See «CHECKING FLUID LEVEL & CONDITION»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e).
4. Start the engine with the transmission in Park range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be discharged during this 30-second run time.
5. If the fluid flow meets or exceeds 2 qts. (1.9L) in 30 seconds, connect the oil cooler feed pipe to the bottom connector on the transmission.
6. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, perform the following diagnosis: Disconnect the flusher discharge hose (5) from the oil cooler return pipe. Disconnect the oil cooler feed pipe at the radiator. Connect the flusher discharge hose (5) to the oil cooler feed pipe, radiator end. Clip the discharge hose (5) onto the oil drain container. Start the engine with the transmission in Park range and run for 30 seconds after fluid begins to flow from the discharge hose (5). A minimum of 2 qts. (1.9L) must be discharged during this 30 second run time.
7. If the amount of transmission fluid flow remains less than 2 qts. (1.9L) in 30 seconds, inspect the oil cooler feed pipe, bottom connector, for restrictions or damage. If no condition is found with the feed pipe, bottom connector, inspect the transmission.

Scheme 90

Clean-Up

1. Disconnect the water supply hose from the transmission oil cooler line flusher and bleed any remaining air pressure from the flusher tank.
2. Remove the fill cap from the flusher and return any unused flushing solution to its container. Rinse the flusher with water. DO NOT store the flusher with flushing solution in it.
3. After every third use, clean the flusher as described in the instructions included with the tool.
4. Dispose of any waste water/solution and transmission fluid in accordance with local regulations.

ON-VEHICLE REPAIRS

Various components may be serviced without transmission removal, depending on application. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on testing electrical components, see appropriate DIAGNOSIS article.

ADJUSTMENTS

PARK/NEUTRAL POSITION SWITCH

With an assistant in driver's seat, raise and support vehicle. The transmission must be in the Park or Neutral positions only. Loosen the Park/Neutral Position (PNP) switch retaining bolts and rotate the switch slightly, while assistant attempts to start engine. After engine starts, turn engine OFF. Tighten PNP switch bolts to specification. See TORQUE SPECIFICATIONS . Ensure vehicle does not start in any range other than Park and Neutral. Replace PNP switch if proper operation cannot be achieved. See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION.

SHIFT CABLE

1. Position the transmission shift control lever into park.
2. Apply the park brake.
3. Raise and suitably support the vehicle.
4. Remove the end of the range selector cable from the range selector lever ball stud. (Scheme 91)
5. Position the transmission range selector lever to park. Rotate the range select lever clockwise until it reaches the full mechanical stop position.
6. Slide the locking tab retainer to the side.
7. Release the locking tab.
8. Install the end of the range selector cable to the range selector lever ball stud.
9. Engage the locking tab without disturbing the cable. This sets the adjustment.
10. Slide the locking tab retainer over the locking tab.
11. Lower the vehicle.
12. Check the transmission for proper operation.
13. Release the parking brake.

Scheme 91

REMOVAL & INSTALLATION

ACCUMULATOR ASSEMBLY

Note. Tools required: Pump and Valve Body Alignment Pin Set (J-25025-B) and Transmission Assembly Lubricant (J-36850).

Removal

1. Raise and support the vehicle.
2. Remove transmission oil pan and filter. NOTE: 1-2 accumulator can be removed without removing the control valve assembly.
3. Remove control valve body. See «VALVE BODY & PRESSURE SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e).
4. Remove accumulator cover retaining bolts. (Scheme 92)
5. Remove 1-2 accumulator cover assembly.
6. Disassemble 1-2 accumulator by blowing compressed air into the 1-2 accumulator cover to remove the accumulator piston. Then remove the 1-2 accumulator inner and outer springs. (Scheme 93)
7. Inspect 1-2 accumulator inner and outer springs for cracks.
8. Remove 1-2 accumulator piston seal (1) from 1-2 accumulator piston. (Scheme 94) Then inspect 1-2 accumulator piston for porosity, cracks, scoring, nicks and scratches.
9. Inspect 1-2 accumulator cover for porosity, cracks, scoring, nicks and scratches.
10. Remove the spacer plate support retaining bolts. (Scheme 95) CAUTION: Use care not to drop the following items that will be removed along with the spacer plate: The number one checkball. The 3-4 accumulator spring. The 3-4 accumulator pin.
11. Remove the spacer plate support.
12. Remove the spacer plate to valve body gasket, spacer plate and spacer plate to transmission case gasket. (Scheme 96)
13. Remove the 3-4 accumulator piston and inspect the 3-4 accumulator spring for cracks. (Scheme 97)
14. Remove the 3-4 accumulator piston seal from the 3-4 accumulator piston and inspect for porosity, cracks, scoring, nicks and scratches.

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Installation

1. Install NEW 3-4 accumulator piston seal to 3-4 accumulator piston. (Scheme 94)
2. Install the 3-4 accumulator pin (1) into transmission case and retain the pin with Transjel(R) Lubricant (J-36850). (Scheme 98)
3. Install 3-4 accumulator piston onto the pin in the transmission case. Ensure that 3-4 accumulator piston legs face away from the transmission case. (Scheme 97)
4. Install the Pump and Valve Body Alignment Pin Set (J-25025-B) (2 and 3) to the transmission case. (Scheme 98)
5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate. Use Transjel(R) lubricant to retain gaskets to the spacer plate. The case gasket is identified by a "C". Be sure to place the case gasket on the transmission case side of the spacer plate. The valve body gasket is identified by a "V". Be sure to place the valve body gasket on the valve body side of the spacer plate.
6. Ensure that the solenoid screens (1 and 2) are in place on the spacer plate. (Scheme 99)
7. Place the checkball (3) on the spacer plate in the location shown.
8. Place the 3-4 accumulator spring (4) on the spacer plate.
9. Install the spacer plate and related components to the transmission.
10. Install the spacer plate support and the spacer plate support retaining bolts. (Scheme 95) Tighten spacer plate support retaining bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. (Scheme 100)
12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston.
13. Install 1-2 accumulator inner and outer springs to 1-2 accumulator cover. (Scheme 101)
14. Install 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover.
15. Install 1-2 accumulator cover and accumulator cover retaining bolts. (Scheme 92) Tighten accumulator cover retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
16. Remove pump and valve body alignment pin set from transmission case.
17. Install control valve body. See «VALVE BODY & PRESSURE SWITCH»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e).
18. Install transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
19. Lower the vehicle, and fill transmission to appropriate level with proper fluid. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

Scheme 98

Scheme 99

Scheme 100

Scheme 101

1. Remove the grille assembly.
2. Place a drain pan under the vehicle.
3. Disconnect the transmission oil cooler lines from the auxiliary oil cooler.
4. Remove the oil cooler lines from the auxiliary oil cooler. See «OIL COOLER LINES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e) .
5. Remove the 4 bolts securing the auxiliary oil cooler to the radiator support.
6. Remove the auxiliary oil cooler.

1. Install the 4 bolts securing the oil cooler to the radiator support. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications) .
2. Install the oil cooler lines to the auxiliary oil cooler. See «OIL COOLER LINES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e) . Tighten the cooler lines to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications) .
3. Remove the drain pan.
4. Install the grille assembly.

Note. Do not remove the valve body for the following procedure. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid.

1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
2. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__accumulator-assembly).
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. see scheme 19 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
4. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 103)
5. Remove the 1-2 and 2-3 shift control solenoid retainers. Remove the 1-2 and 2-3 shift control solenoids. (Scheme 104)
6. Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 104)

Scheme 102

Scheme 103

Scheme 104

1. Install the 3-2 control solenoid. Install the 3-2 control solenoid retainer. (Scheme 104)
2. Install the 1-2 and 2-3 shift control solenoids. Install the 1-2 and 2-3 shift control solenoid retainers. (Scheme 104)
3. Install the pressure control solenoid. Ensure the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
4. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. see scheme 19 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 control solenoid.
5. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__accumulator-assembly).
6. Install the oil filter and oil pan. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
7. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

EXTENSION HOUSING REAR OIL SEAL

Note. Tools required: Rear Extension Seal Installer (J-21426).

Raise and support the vehicle. Place drain pan under vehicle. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove the rear extension oil seal. Use a flat bladed tool and carefully pry the seal from the housing. (Scheme 105) Inspect case housing for damage. Replace extension housing if necessary.

Scheme 105

Lubricate inside diameter of the NEW seal with Transjel(R) Lubricant (J-36850). Install the new seal using seal installer and a soft faced mallet. (Scheme 106) Install the seal to the extension housing. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove drain pan and lower the vehicle. Fill transmission with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

Scheme 106

1. Remove the transmission fluid level indicator from the fluid fill tube. Remove engine cover. Remove the bolt securing the transmission fluid fill tube bracket to the engine. Raise and support the vehicle. Remove the bolt securing the transmission fluid fill tube bracket to the transmission. Remove the transmission pan drain plug. Drain the fluid into an approved container. (Scheme 107)
2. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. Remove the transmission fluid fill tube from the transmission.
3. Pull the tube upward from the transmission. Remove the transmission fill tube seal. Clean the metal parts using solvent. DO NOT allow the solvent to enter the transmission. Dry the parts using compressed air.

Scheme 107

1. Install a new filler tube seal into the transmission case. Install the filler tube into the seal. (Scheme 107)
2. Lower the vehicle. Install the upper transmission fill tube to the vehicle and into the lower fill tube. Tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
3. Install the bolt securing the filler tube bracket to the engine and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
4. Install the oil level indicator. Adjust fluid level as necessary. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

1. Remove the upper oil cooler line from the radiator. Raise and support the vehicle. If equipped with AWD, remove the engine protector shield. Remove the lower cooler line from the radiator. (Scheme 108) NOTE: Perform the following procedures when removing the retaining ring and cooler line from the quick connect fitting on the radiator and transmission.
2. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 2 inches. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. (Scheme 109)
3. Remove the retaining ring from the quick connect fitting. Discard the retaining ring. Pull the cooler line straight out from the quick connect fitting. (Scheme 110)
4. Remove the retaining ring (E-clip) securing the cooler line to the quick connect to remove the remaining cooler lines from the remaining quick connect fittings. Remove the cooler lines from the vehicle.

Scheme 108

Scheme 109

Scheme 110

Note. Do not reuse any of the existing oil lines or oil line fittings if there is any excessive corrosion. Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be NEW. Ensure the following procedures are performed when installing the new retaining rings onto the fittings.

1. Install the transmission oil cooler line to the vehicle.
2. Install a new retaining ring (E-clip) into the quick connect fitting using the following procedure: Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 111) Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears through the 3 slots on the fitting. (Scheme 112) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 113)
3. Ensure the 3 retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. (Scheme 114)
4. Install the new retaining rings (E-clips) into the remaining quick connect fittings. NOTE: Ensure the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation.
5. Install the cooler lines to the vehicle. Install the cooler line into the quick connect fitting. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. (Scheme 115) NOTE: Do not use the plastic cap on the cooler line to install the cooler line into the fitting. (Scheme 116)
6. Pull back sharply on the cooler line to ensure the cooler line is fastened into the quick connect fitting. Position (snap) the plastic cap onto the fitting. (Scheme 117) DO NOT manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. Ensure the plastic cap is fully seated against the fitting.
7. Ensure no gap is present between the cap and the fitting. (Scheme 118) Ensure the Yellow identification band on the tube is hidden within the quick connect fitting. (Scheme 119) A hidden Yellow identification band indicates proper joint seating.
8. DO NOT install the cooler line end into the fitting incorrectly. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting per Step 5 of the cooler line removal procedure. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall per step 2 of the cooler line installation procedure.
9. Install the cooler lines into the retaining clip at the oil pan. Install the flair nut securing the lower oil cooler line to the radiator. Tighten the flair nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
10. Lower the vehicle. Install the flare nut securing the upper cooler line to the radiator. Tighten the flair nut to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications). Start the engine.

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Note. Tools required: Neutral Position Switch Adjustment Tool (J-41364-A).

1. Apply the parking brake. Shift the transmission into Neutral. Raise the vehicle.
2. Remove the nut securing the transmission control lever to the manual shaft. Remove the transmission control lever from the manual shaft. (Scheme 120)
3. Disconnect the wiring harness connector from the PNP switch.
4. Remove the bolts securing the PNP switch to the transmission. Remove the PNP switch from the manual shaft.

Scheme 120

1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. (Scheme 121) Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. CAUTION: If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary.
2. Install the switch to the transmission with two bolts finger tight. (Scheme 121) Position the Neutral Position Adjustment Tool (J-41364-A) onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool.
3. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
4. Remove the neutral position adjustment tool from the switch. If installing a new switch, remove the positive assurance bracket at this time. Connect the electrical connectors to the switch.
5. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
6. Lower the vehicle. Check the switch for proper operation. The engine must start in the Park or Neutral positions only. If proper operation of the switch can not be obtained, replace the switch.
7. If vehicle does not operate as specified, readjust the PNP switch.

Scheme 121

1. Raise and support the vehicle. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. (Scheme 122)
3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). (Scheme 123)
5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). Remove the pressure regulator valve (1). (Scheme 123)

Scheme 122

Scheme 123

1. Install the pressure regulator valve (1). Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). (Scheme 123)
2. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. (Scheme 123)
3. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot.
4. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. (Scheme 122) Install the transmission oil filter and oil pan. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
5. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

1. Apply the parking brake. Position the steering column shift lever to Park. Remove the knee bolster trim panel.
2. Remove the clip securing the shift cable to the steering column bracket. Remove the shift cable from the steering column shift control. Pull back the carpet and insulation to gain access to the shift cable pass-through grommet.
3. Remove the rubber grommet from the floor panel. Raise the vehicle. (Scheme 91)
4. Remove the shift cable from the stud ball. Remove the locking clip from the cable at the bracket. Unclip the cable from the retainers at the fuel lines and body. Lower the vehicle. Remove the cable from the vehicle.

Note. Prior to installing the shift cable to the vehicle, ensure that the column shift lever and the transmission control lever are in the mechanical park position. The transmission control lever can be positioned to mechanical park by rotating the control lever clockwise until it reaches its full clockwise position.

1. Install the shift cable to the vehicle. Raise the vehicle. Remove the black shipping tab from the transmission end of the shift cable and discard the tab.
2. Install the shift cable to the transmission bracket. (Scheme 91) Install the cable clip. Install the shift cable end to the transmission shift control lever by pushing the cable end onto the transmission shift control lever stud ball. Lock the primary lock. Lock the secondary lock. Attach the shift cable to the fuel line and body clips. Lower the vehicle. NOTE: Ensure the shift lever is in the Park position.
3. Install the rubber grommet to the floor panel. Install the shift cable to the steering column shift control. Install the clip securing the shift cable to the steering column bracket. Install the cable to the shift lever ball stud.
4. Adjust shift cable. See «SHIFT CABLE»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__shift-cable) under ADJUSTMENTS. Install the knee bolster bracket. Install the knee bolster trim panel.

TCC SOLENOID, TCC PWM SOLENOID & WIRING HARNESS

Note. For all other solenoids, see control valve body replacement.

Note. Tools required: Power Piston Seal Protector and Diaphragm Retainer Installer (J-28458).

1. Raise and support the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
2. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 125) Depress both tabs on the connector and pull straight up, DO NOT pry the connector. NOTE: Removal of the valve body is not necessary for the following procedure.
3. Remove the 1-2 accumulator assembly. DO NOT remove the spacer plate. See «ACCUMULATOR ASSEMBLY»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__accumulator-assembly).
4. Disconnect the internal wiring harness electrical connectors from the transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift control solenoid. (Scheme 124)
5. Remove the TCC PWM solenoid retainer. Remove the TCC PWM solenoid to access one of the TCC solenoid retaining bolts. (Scheme 126)
6. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. see scheme 44 Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 127)
7. Using power piston seal protector and diaphragm retainer installer, release the pass-through electrical connector from the transmission case. (Scheme 128) Use the small end of the power piston seal protector and diaphragm retainer installer over the top of the connector. Twist to release the 4 tabs retaining the connector. Pull the harness connector down through the transmission case.
8. Remove the TCC solenoid (with "O" ring seal) and wiring harness assembly from the transmission case.
9. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage, cracked connectors, exposed wires and loose pins. see scheme 47

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

1. Install the wiring harness and TCC solenoid assembly with a new "O" ring seal to the transmission. Install the pass-through electrical connector to the transmission case. (Scheme 128)
2. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. (Scheme 127) Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
3. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
4. Install the pressure control solenoid. see scheme 44 Ensure the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
5. Install the TCC PWM solenoid to the control valve body. (Scheme 126) Install the TCC PWM solenoid retainer.
6. Connect the internal wiring harness electrical connectors to the transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift control solenoid. (Scheme 93)
7. Install the 1-2 accumulator. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down. (Scheme 125)
8. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

1. Ensure removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission. (Scheme 129) Torque converter clutch solenoid (1). Pressure control solenoid (2). Internal wiring harness (3). 2-3 shift control solenoid (4). 1-2 shift control solenoid (5). Transmission fluid pressure manual valve position switch (6). 3-2 shift control solenoid (7). Torque converter clutch pulse width modulation solenoid (8).
2. Remove the fluid level indicator. Raise and support the vehicle. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION.
3. Disconnect the internal wiring harness electrical connectors from the transmission fluid pressure manual valve position switch (1), 1-2 shift control solenoid (2), 2-3 shift control solenoid (3), pressure control solenoid (4), TCC PWM solenoid (5) and the 3-2 shift control solenoid (6).
4. Remove the fluid indicator stop bracket bolt. (Scheme 130) Remove the fluid indicator bracket (1). Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible.
5. Remove the TCC PWM solenoid (1) to access the TCC solenoid retaining bolts. (Scheme 126) Remove the TCC solenoid retaining bolts. (Scheme 131) Remove the TCC solenoid (with "O" ring seal) and wiring harness from the control valve body.
6. Reposition the harness to the side of the transmission case. (Scheme 128) Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 132) Remove the transmission fluid pressure switch. Inspect the transmission fluid pressure switch for damage or debris. (Scheme 133)
7. Remove the manual detent spring retaining bolt. Remove the manual detent spring. (Scheme 134) Inspect the manual detent spring for cracks or damage. CAUTION: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages.
8. Remove the remaining control valve body bolts. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. (Scheme 135)
9. If disassembly of the control valve body is necessary, see appropriate OVERHAUL article.

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

1. Install the 7 checkballs in the valve body. (Scheme 136) Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 135)
2. Verify the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). (Scheme 137) Install one bolt (M6 X 1.0 X 47.5) hand-tight in the center (1) of the valve body to hold it in place. (Scheme 138) DO NOT install the transmission fluid indicator stop bracket and bolt at this time. NOTE: When installing bolts throughout this procedure, ensure to use the correct bolt size and length in the correct location as specified.
3. Install but do not tighten the control valve body bolts which retain only the valve body directly. (Scheme 139) Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: M6 X 1.0 X 65.0 (1). M6 X 1.0 X 54.4 (2). M6 X 1.0 X 47.5 (3). M6 X 1.0 X 35.0 (4). M8 X 1.0 X 20.0 (5). M6 X 1.0 X 12.0 (6). M6 X 1.0 X 18.0 (7).
4. Install the manual detent spring. Install but DO NOT tighten the manual detent spring retaining bolt. (Scheme 134) Install the transmission fluid pressure switch. (Scheme 132) Install but DO NOT tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 132) NOTE: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation.
5. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. (Scheme 139) Tighten the control valve body bolts (in sequence) to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
6. Ensure the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
7. Install the TCC solenoid with a new "O" ring seal to the valve body. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
8. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. Place the tab between the valve body and the pressure switch in the location shown (2). (Scheme 128) Press the harness into position on the valve body bolt bosses (1 and 3).
9. Install the TCC PWM solenoid (1) to the control valve body. Install the TCC PWM solenoid retainer (2). (Scheme 126)
10. Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 130) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications).
11. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch (1). (Scheme 102) The 1-2 shift control solenoid. The 2-3 shift control solenoid. The pressure control solenoid. The TCC PWM solenoid. The 3-2 shift control solenoid.
12. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__draining-refilling) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Raise and support the vehicle. Remove the electrical connector from the speed sensor. Remove the bolt. (Scheme 140) Remove the speed sensor and the "O" ring seal. Inspect the seal and the transmission case. Replace the seal, if necessary.

Scheme 140

Install the speed sensor and the "O" ring seal into the transmission. (Scheme 140) Install the bolt. Tighten the bolt to specification. See TORQUE SPECIFICATIONS. Install the electrical connector to the speed sensor. Lower the vehicle. Check transmission fluid level and fill if necessary. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

2-4 SERVO

Note. Tools required: Servo Cover Depressor (J-29714-A).

1. Raise and support the vehicle. Remove the 2 heat shield retaining bolts and the heat shield from the transmission. Remove the oil pan bolt below and to the left of the 2-4 servo cover. Install the servo cover depressor to the oil pan rail. Tighten the bolt on the servo cover depressor in order to compress the servo cover. (Scheme 141)
2. Remove the servo cover retaining ring. (Scheme 142) Loosen the bolt on the servo cover depressor to release tension on the servo cover. Remove the servo cover and "O" ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the "O" ring seal before removing the cover. (Scheme 143)
3. Remove the 2-4 servo assembly from the transmission. Inspect the 4th apply piston, the 2-4 servo converter, 2nd apply piston and the piston inner housing for cracks, scoring, burrs and nicks.

Scheme 141

Scheme 142

Scheme 143

1. Install the new seals on the pistons and the servo cover. Lubricate the seals with clean transmission fluid. Install the 2-4 servo assembly into the 2-4 servo bore. Install the servo cover and "O" ring seal.
2. Install the servo cover depressor. (Scheme 141) Tighten the bolt on the servo cover depressor in order to compress the servo cover. Install the servo cover retaining ring. Remove the servo cover depressor from the oil pan flange.
3. Install the oil pan bolt. Tighten the oil pan bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications). Install the 2 heat shield retaining bolts and the heat shield from the transmission. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__torque-specifications). Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l60-e__fluid-capacities) under LUBRICATION.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• AUXILIARY OIL COOLER
• DRAINING & REFILLING
• OIL COOLER FLUSHING & FLOW CHECK
• TORQUE SPECIFICATIONS
• RECOMMENDED FLUIDS
• FLUID CAPACITIES
• ADJUSTMENTS
• REMOVAL & INSTALLATION
• ACCUMULATOR ASSEMBLY
• SHIFT CABLE