Automatic Transmission Servicing (4l80-e) Chevrolet Chevy Express H2500

APPLICATION

TRANSMISSION APPLICATION

Scheme 230

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 color Red? If so, go to next step. If not, go to step 11 .
2. Is the fluid level satisfactory? If so, system is okay. If not, go to next step.
3. Check the fluid. Is the fluid foamy? If so, go to step 8 . If not, go to next step.
4. Check the fluid level. The proper fluid level should be in the middle of the cross-hatched area. Is the level high? If so, go to step 9 . If not, go to next step.
5. The fluid will be low. Add fluid to the proper fluid level. After repairs, go to next step.
6. Check for external leaks. Were any leaks found? If so, go to next step. If not, go to step 20 .
7. Correct the leak condition. After repairs, go to step 20 .
8. Is the fluid level too high? If so, go to next step. If not, go to step 10 .
9. Remove excess fluid to the proper fluid level. Is the fluid level satisfactory? If so, go to step 20 .
10. Check for contaminants in the fluid. Drain the fluid to determine the source of the contamination. Was the fluid drained? If so, go to step 15 .
11. Is the fluid color non-transparent Pink? If so, go to next step. If not, go to step 13 .
12. Replace the cooler. After repairs, go to step 15 . NOTE: Transmission fluid may turn dark with normal use. This does not always indicate oxidation or contamination.
13. The fluid color should be Light Brown. Is the fluid color Light Brown? If so, go to next step.
14. Drain the fluid to determine if the fluid is contaminated. Was the fluid contaminated? If so, go to next step. If not, go to step 18 .
15. Perform root cause and repair as necessary. See appropriate OVERHAUL article. Is the overhaul complete? If so, go to next step.
16. Using scan tool, press clear TRANS ADAPT function. Are the reset procedures complete? If so, go to next step.
17. Add new fluid. Is the procedure complete? If so, go to step 20 .
18. Change the fluid and the filter. After repairs, go to step 19 .
19. Are the reset procedures complete? If so, go to next step.
20. Is the fluid level satisfactory? If so, system 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

1. Raise and support the vehicle. Place drain pan under transmission oil pan. Remove oil pan drain plug, if equipped.
2. Remove oil pan bolts and oil pan. Remove the gasket and magnet. (Scheme 231) Remove oil filter. After proper removal of oil filter, remove filter neck seal.
3. Transmission oil pan gasket is reusable. Inspect gasket and replace as needed. Clean transmission case and oil pan gasket surfaces with solvent.
4. To reassemble, install filter neck seal and oil filter. Install oil pan gasket to the pan. Install magnet into the bottom of the pan.
5. Install oil pan to transmission with 17 bolts. Tighten oil pan to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
6. Apply small amount of sealant (GM P/N 12346004) to drain plug threads, if equipped.
7. Install the oil pan drain plug, if equipped. Tighten drain plug to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
8. 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-4l80-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__fluid-capacities). Check the COLD fluid level reading for initial fill only. Inspect the oil pan gasket for leaks.

Scheme 231

OIL COOLER FLUSHING & FLOW CHECK

Note. Do not use solutions that contain alcohol or glycol. Use of solutions that contain alcohol or glycol may damage flushing equipment, oil cooler components and/or transmission components.

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 232) 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 232

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 233)
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 234) 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 233

Scheme 234

Forward Flush

1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. (Scheme 233) 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 234)
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 235)
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-4l80-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 235

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 236)
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 236

REMOVAL & INSTALLATION

Removal

1. Remove the grille assembly.
2. Disconnect the 2 lines from the auxiliary cooler.
3. Remove the lines from the push clips on the auxiliary cooler mounting bracket.
4. Raise the vehicle.
5. Remove the lower bolts from the auxiliary cooler mounting bracket.
6. Lower the vehicle.
7. Remove the upper bolts.
8. Remove the auxiliary oil cooler from the vehicle.

Installation

1. Install the oil cooler into the vehicle.
2. Install the upper bolts into the oil cooler bracket. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications) .
3. Raise the vehicle.
4. Install the lower bolts to the oil cooler bracket. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications) .
5. Lower the vehicle.
6. Connect the oil cooler lines to the auxiliary oil cooler.
7. Attach the oil cooler lines to the push clips in the mounting bracket.
8. Reinstall the grille assembly.

1. The following components can be serviced without removing the valve body from the transmission. Ensure that removal of the valve body is necessary before proceeding. (Scheme 237) The 2-3 solenoid (1). The internal wiring harness (2). The 1-2 shift solenoid (3). The transmission fluid temperature sensor (4). The transmission fluid pressure manual valve position switch (5). The pressure control solenoid (6). The Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid (7).
2. Remove the fluid level indicator. (Scheme 238)
3. Raise the vehicle.
4. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__draining-refilling) under LUBRICATION.
5. Disconnect the internal wire harness from the Transmission Fluid Pressure (TFP) manual valve position switch. CAUTION: Use care not to loose the 5 "O" rings that are located between the TFP manual valve position switch and the valve body.
6. Remove the control valve body bolts (1) that retain the TFP manual valve position switch (2) to the control valve body. (Scheme 239)
7. Remove the TFP manual valve position switch.
8. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components.
9. Remove the lube oil pipe bolt (6) and retainer (7). (Scheme 240)
10. Remove the lube oil pipe (5). (Scheme 240)
11. Remove the bolts and remove the manual shaft detent spring (3). (Scheme 240) CAUTION: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in transmission case passages.
12. Remove the remaining control valve body bolts.
13. Carefully lower the valve body down from the transmission case. Use care not to drop the manual shaft valve.
14. Remove the control valve assembly (2) which includes the following: The accumulator housing assembly (1). (Scheme 240) The control valve assembly to the spacer plate gasket. The spacer plate.
15. Remove the manual valve (1) from the control valve body. (Scheme 241)
16. Inspect the manual valve for nicks and burrs.
17. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. (Scheme 242)
18. Remove the PWM screen (1) from the case passage. (Scheme 242)
19. Remove the manual 2-1 band servo assembly (1). (Scheme 243)
20. Remove the servo piston cushion spring (2). (Scheme 243)
21. Remove the manual 2-1 band servo piston pin retainer ring (4). (Scheme 244)
22. Remove the manual 2-1 band servo piston pin (1). (Scheme 244)
23. Remove the manual 2-1 band servo piston seal (2). (Scheme 244) CAUTION: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick.
24. Remove the eight checkballs (nine checkballs for some models). (Scheme 245)

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

1. Install the 8 checkballs (9 checkballs for some models) into the control valve body. The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only. To hold the checkballs in place, use the Transjel(R) Lubricant (J-36850).
2. Install the PWM screen into the control valve body. (Scheme 246)
3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). (Scheme 244)
4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). (Scheme 244)
5. Install the manual 2-1 band servo piston pin retainer ring (4). (Scheme 244)
6. Install the manual 2-1 band servo piston cushion spring (2). (Scheme 243) CAUTION: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band.
7. Install the manual 2-1 band servo piston assembly (1).
8. Install the manual valve (1) into the control valve body. (Scheme 241)
9. To aid in alignment and assembly, install tool Guide Pins (J-25025).
10. Install the control valve body gasket (6). (Scheme 246)
11. Install the control valve body assembly (5). Attach the manual valve to the detent lever while installing the control valve body assembly.
12. Install the transmission fluid pressure manual valve position switch (2).
13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight.
14. Tighten the bolts in the order shown. (Scheme 247) Tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
15. Remove the guide pins.
16. Install the manual shaft detent roller and spring assembly (3) and bolts. (Scheme 240)
17. Install the two wiring harness clips (1) and bolts (2).
18. Install the wiring harness clip (1) and bolts (2).
19. Install the lube oil pipe (5) with the short end into the control valve body.
20. Install the lube oil pipe retainer (7) and bolt (6).
21. Install the control valve body bolts. Tighten the bolts in the order shown. Tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
22. Install the remaining control valve body bolts. Tighten the remaining bolts specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
23. Connect the internal wiring harness to the valve body electrical components.
24. Install the oil pan, gasket and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__draining-refilling) under LUBRICATION.
25. Lower the vehicle.
26. Fill the transmission to the proper level with appropriate transmission fluid. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__fluid-capacities) under LUBRICATION.

Scheme 246

Scheme 247

EXTENSION HOUSING REAR OIL SEAL

Note. Tools required: Rear Lubricant Seal Installer (J-41505), Slide Hammer Adapter (J-6125-1B), Universal Seal Remover (J-23129) and Transjel(R) Lubricant (J-36850).

Raise and support the vehicle. Place a drain pan under the vehicle. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove the output shaft seal (3) from the extension housing (4) using the slide hammer adapter and the universal seal remover. (Scheme 248) Inspect the case extension housing for damage. Replace the extension housing if necessary.

Scheme 248

Lubricate the inside diameter of the new seal with assembly lubricant. Use the rear lubricant seal installer with a soft faced mallet to install the seal (2). (Scheme 249) Install the seal (2) to the extension housing (3). Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove the drain pan and lower the vehicle. Fill transmission with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

Scheme 249

1. Remove the engine air cleaner. Remove the transmission fluid level indicator from the fluid fill tube. Remove the engine cover. Remove the bolt and the nut securing the transmission fluid fill tube to the engine.
2. Remove the nut securing the transmission fluid fill tube to the transmission stud. (Scheme 250) Remove the upper fill tube from the vehicle. Raise and support the vehicle.
3. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. Remove the drain plug from the transmission. Drain the fluid into an approved container. Remove the transmission fluid fill tube from the transmission. Pull the tube upward from the transmission.
4. Remove the transmission fill tube seal. Clean the metal parts using solvent. DO NOT allow the solvent to enter the transmission. Air dry the parts.

Scheme 250

1. Install a NEW oil level indicator tube seal into the transmission case. Install the bottom of oil level indicator tube into the seal. (Scheme 250) Remove the safety stands. Lower the vehicle.
2. Install the upper fill tube to the vehicle. Install the bolt and the nut securing the oil level indicator tube brackets to the engine. Tighten the bolt and nut to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
3. Install the nut securing the oil level indicator tube to the transmission stud and tighten the nut to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications). On all models, install the air cleaner.
4. Install the oil level indicator. Install air cleaner. Install engine cover. Adjust fluid level as necessary. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__fluid-capacities) under LUBRICATION.

1. Raise and support the vehicle. Remove the oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__draining-refilling) under LUBRICATION.
2. Remove the 6 forward servo cover bolts, cover and gasket.
3. Remove the following parts: Forward servo piston pin (5). (Scheme 251) "O" ring seal (4). Servo piston (3). Retainer (2). Piston spring (1).

Scheme 251

1. Install the following parts: Piston spring (1). (Scheme 251) Retainer (2). Servo piston (3). O-ring seal (4). Forward servo piston pin (5).
2. Install the 6 forward servo gasket, cover and 6 bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications).
3. Install the oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-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-4l80-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__fluid-capacities) under LUBRICATION.

1. Raise the vehicle. Support the vehicle with safety stands. Remove the 2 oil cooler lines from the radiator. (Scheme 252) If equipped with the auxiliary transmission oil cooler, remove the outlet pipe from the auxiliary cooler pipe.
2. Remove the 2 oil cooler lines from the transmission. Remove the 2 oil cooler lines from the clips on the frame rail. NOTE: Perform the following procedures when removing the retaining ring and cooler line from the quick connect fitting on the transmission.
3. Pull the plastic cap back from the quick connect fitting and down along the cooler line about two inches. (Scheme 254) Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.
4. Remove the retaining ring from the quick connect fitting. (Scheme 253) Discard the retaining ring. Pull the cooler line straight out from the quick connect fitting.
5. Remove the retaining ring (E-clips) securing the cooler line to the quick connect in order to remove the remaining cooler lines from the remaining quick connect fittings. Remove the cooler lines from the vehicle. Lower the vehicle.

Scheme 252

Scheme 253

Scheme 254

1. Raise the vehicle. Install the transmission oil cooler line to the vehicle. NOTE: 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.
2. Install the new retaining ring (E-clip) into the quick connect fitting. Install the 2 cooler lines to the radiator. If equipped with the auxiliary oil cooler, install the inlet line to the radiator and the outlet to the auxiliary cooler line. Install the 2 oil cooler lines to the transmission.
3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 255) Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. (Scheme 256) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. (Scheme 257)
4. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. (Scheme 258) Install the new retaining ring (E-clip) into the remaining quick connect fittings. NOTE: Ensure that 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 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 259)
6. DO NOT use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 260) Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
7. Position (snap) the plastic cap onto the fitting. DO NOT manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. Ensure that the plastic cap is fully seated against the fitting. (Scheme 261) Ensure that no gap is present between the cap and the fitting. (Scheme 262)
8. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. DO NOT install the cooler line into the fitting incorrectly. (Scheme 263)
9. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting per step 3 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 1 of the cooler line installation procedure. Install the cooler line into the quick connect fitting again in order to install the remaining cooler lines into the remaining quick connect fittings.
10. Install the engine or transmission cooler lines to the frame. Lower the vehicle.

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

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 264)
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 264

1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. (Scheme 265) 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 265) 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-4l80-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-4l80-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 265

1. Raise 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-4l80-e__draining-refilling) under LUBRICATION. WARNING: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result.
2. Remove the reverse boost valve bushing retainer ring (2). (Scheme 266)
3. Remove the following from the reverse boost valve cylinder: Reverse boost valve bushing. (Scheme 267) Reverse boost valve. Pressure regulator spring retainer. Pressure regulator spring. Pressure regulator valve. Reverse boost valve bushing.

Scheme 266

Scheme 267

1. Install the pressure regulator valve with Transjel(R) Lubricant (J-36850).
2. Pre-assemble the following parts: Reverse boost valve bushing. (Scheme 267) NEW reverse boost valve. NEW pressure regulator spring retainer. Added isolator pressure regulator spring. Pressure regulator spring.
3. Install the pre-assembled parts into the pump bore.
4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. (Scheme 266)
5. Install the transmission oil pan and the oil filter. 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-4l80-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__fluid-capacities) under LUBRICATION.

Remove the transmission oil pan and filter. See DRAINING & REFILLING under LUBRICATION. Remove the rear servo assembly from the transmission case as follows

1. Cover bolts (6). (Scheme 268)
2. Cover (5).
3. Cover gasket (4).
4. Bottom retaining clip (3).
5. Servo piston (2).
6. Outer ring oil seal (1).
7. Inner ring oil seal (7).
8. Accumulator piston (8).
9. Piston seal (9).
10. Washer (10).
11. Servo spring (11).
12. Servo spring retainer (12).
13. Selective pin (13).
14. Accumulator spring (14).

Scheme 268

1. Install the rear servo assembly into the transmission case as follows: Accumulator spring (14). Selective pin (13). Servo spring retainer (12). Servo spring (11). Washer (10). Piston seal (9). Accumulator piston (8). Inner ring oil seal (7). Outer ring oil seal (1). Servo piston (2). Bottom retaining clip (3). Cover gasket (4). Cover (5). Cover Bolt (6).
2. Install the cover bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__torque-specifications) .
3. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__draining-refilling) under LUBRICATION. Lower vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__recommended-fluids) and «FLUID CAPACITIES»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__fluid-capacities) under LUBRICATION.

1. Apply the parking brake. Position the steering column shift lever to Park. Remove the knee bolster trim panel. Remove the knee bolster bracket.
2. Remove the clip securing the shift cable to the steering column bracket. Remove the shift cable from the steering column shift control. Remove the rubber grommet from the floor panel. Remove the air cleaner assembly.
3. Remove the shift cable clips from the left front of the engine compartment. Raise the vehicle. Remove the shift cable clips from the left rear engine bracket. (Scheme 236)
4. Remove the shift cable from the stud ball. Remove the locking clip from the cable at the bracket. Lower the vehicle. Remove the shift 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.
2. Remove the black shipping tab from the transmission end of the shift cable and discard the tab. Install the ball stud on the transmission.
3. Install the shift cable to the transmission bracket. (Scheme 236) 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.
4. Install the shift cable clips to the engine brackets. Lower the vehicle. NOTE: Ensure the shift lever is in the Park position.
5. 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. Adjust the shift cable. See «SHIFT CABLE»(/chevrolet/chevy-express-h2500/2003-2003/remont/automatic-trans/#automatic-transmission-servicing-4l80-e__shift-cable) under ADJUSTMENTS. Install the knee bolster bracket. Install the knee bolster trim panel.

Raise and support the vehicle. Remove the oil pan and the filter. See DRAINING & REFILLING under LUBRICATION. Remove the valve bore plug retainer ring. (Scheme 269) Remove the plug. Remove the valve. Remove the spring.

Scheme 269

Install the spring, the valve and the plug. (Scheme 269) Install the valve bore plug retainer ring. Install the filter and the oil pan. See DRAINING & REFILLING under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

VEHICLE SPEED SENSORS

Note. The output speed sensor procedure is for 2WD vehicles. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case.

Disconnect the speed sensor connectors (2). Remove the vehicle speed sensor bolts. Remove the vehicle speed sensors (1) and the bracket assemblies from the case. (Scheme 270) Inspect the vehicle speed sensor assemblies (1) for any evidence of damage.

Scheme 270

Lubricate the input speed sensor seal with automatic transmission fluid. Install the vehicle speed sensors (1) and the bracket assemblies on the case. (Scheme 270) Install the bolts and tighten to specification. See TORQUE SPECIFICATIONS. Connect the speed sensor connectors (2). Lower the vehicle.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TRANSMISSION FLUID CAPACITIES
• TORQUE SPECIFICATIONS
• RECOMMENDED FLUIDS
• FLUID CAPACITIES
• ADJUSTMENTS
• REMOVAL & INSTALLATION
• DRAINING & REFILLING
• SHIFT CABLE