APPLICATION
| Application | Transmission Model (RPO Code) |
| Corvette | 4L60-E (M30) |
Identifying Oil Pan Gasket (Hydra-Matic 4L60-E). Scheme 114
Scheme 114: Identifying Oil Pan Gasket (Hydra-Matic 4L60-E)
LUBRICATION
| CAUTION | Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force, and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. |
Note. The Corvette 4L60-E transmission is not equipped with a fluid dipstick.
SERVICE INTERVALS
Change the automatic transmission fluid and filter every 50,000 miles if the vehicle is mainly driven under one or more of these conditions
- In heavy traffic where the outside temperature regularly reaches 32°C (90°F) or higher.
- In hilly or mountainous terrain.
- Uses such as high performance operation.
If the vehicle is not used under any of these conditions, change the fluid and filter every 100,000 miles.
CHECKING FLUID LEVEL & CONDITION
| CAUTION | The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. |
Note. The transmission fluid may darken with normal use and does not always indicate contamination or oxidation.
- Start the engine and allow the engine to idle until the transmission fluid temperature has reached 30-50°C (86-122°F). Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the PARK range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the PARK range. Remove the transmission plug. (Scheme 115) Check the fluid color. If necessary, use a small screwdriver as a dipstick. Is the fluid color clear red or light brown with no burnt odor? If so, go to step 4. If not, go to next step.
- Does the fluid have a burnt odor or a dark brown color? If so, go to step 8. If not, go to next step.
- Does the fluid have a cloudy or milky appearance? If so, go to step 7. If not, go to step 8.
- Check the fluid level. The fluid level should be even with the bottom of the threaded plug hole. Is the fluid level low? If so, go to next step. If not, go to step 11.
- Add appropriate automatic transmission fluid in increments of 0.5L until the fluid drains from the plug hole. See «RECOMMENDED FLUIDS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__recommended-fluids). Did you add more than 1.5L to the transmission? If so, go to next step. If not, go to step 11.
- The transmission may have a leak. Inspect as necessary. Was a transmission fluid leak found? If so, go to step 9. If not, go to step 11.
- The transmission fluid is contaminated with engine coolant. Repair or replace the transmission cooler in the radiator. Is the transmission cooler repair complete? If so, go to step 9.
- Drain the fluid by removing the bottom pan. Check the bottom pan for any excessive debris. Was excessive debris found? If so, go to next step. If not, go to step 10.
- Repair the transmission if required (in some cases, overhaul may be required). See appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS. Flush the transmission oil cooler and pipes and check flow. See «OIL COOLER FLUSHING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__oil-cooler-flushing) and «TRANSMISSION & OIL COOLER FLOW CHECK»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__transmission-oil-cooler-flow-check) under LUBRICATION. Add enough fluid to bring the fluid level to the bottom of the threaded plug hole. Start the engine and allow the engine to idle until the transmission fluid temperature has reached 30-50°C (86-122°F). Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the PARK range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the PARK range. Remove the transmission plug. If needed, add fluid in increments of 0.5L until the fluid drains from the threaded plug hole. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Wipe any excess fluid from the transmission with a rag or shop towel. Is repair complete? If so, road test vehicle. See ROAD TEST under PERFORMANCE TESTS in appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.
- Change the fluid and the fluid filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling). Start the engine and allow the engine to idle until the transmission fluid temperature has reached 30-50°C (86-122°F). Depress the brake pedal and move the shift lever through the gear ranges, pausing a few seconds in each range. Return the shift lever to the PARK range. Raise the vehicle on a hoist. The vehicle must be level with the engine running and the shift lever in the PARK range. Remove the transmission plug. If needed, add fluid in increments of 0.5L until the fluid drains from the threaded plug hole. Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Wipe any excess fluid from the transmission with a rag or shop towel. Is repair complete? If so, road test vehicle. See ROAD TEST under PERFORMANCE TESTS in appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.
- Allow fluid to finish draining out of the plug hole. Install the plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Wipe any excess fluid from the transmission with a rag or shop towel. Is repair complete? If so, road test vehicle. See ROAD TEST under PERFORMANCE TESTS in appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.
RECOMMENDED FLUIDS
Manufacturer recommends Dexron-III automatic transmission fluid. Fill transmission with appropriate quantity. See FLUID CAPACITIES .
FLUID CAPACITIES
| Application | Drain & Refill (2) - Qts. (L) | Overhaul - Qts. (L) |
| 4L60-E | 5.0 (4.7) | 10.8 (10.2) |
| (1) Fluid capacities listed are approximate. Always fill as specified in procedure. See CHECKING FLUID LEVEL & CONDITION . (2) Drain and refill capacity does not include torque converter. |
| (2) | Drain and refill capacity does not include torque converter. |
TRANSMISSION FLUID CAPACITIES (1)
DRAINING & REFILLING
| WARNING | When the transmission is at operating temperatures, take necessary precautions when removing the check/fill plug, to avoid being burned by draining fluid. |
- Raise and suitably support the vehicle. Place a drain pan under the transmission. Clean any dirt from around the transmission check/fill plug. Remove the transmission fluid check/fill plug and allow the fluid to drain. (Scheme 115)
- Support the transmission oil pan. Remove the transmission oil pan bolts. Loosely reinstall the fluid check/fill plug. Lightly tap the oil pan with a rubber mallet or pry gently in order to loosen the pan. Remove the transmission oil pan. (Scheme 116) Drain the remaining fluid from the oil pan.
- Grasp firmly while pulling down with a twisting motion in order to remove the filter. Remove the filter seal. 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. (Scheme 117)and (Scheme 118).
- Inspect the transmission fluid. See «CHECKING FLUID LEVEL & CONDITION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-level-condition). Inspect the transmission fluid filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain evidence for root cause diagnosis: Clutch material. Bronze slivers indicating bushing wear. Steel particles.
- Clean the oil pan gasket mating surfaces, on both the transmission case and the transmission oil pan, with solvent and air dry. Coat the new filter seal with a small amount of Transjel(tm) (J 36850) or equivalent. Install the new filter seal into the transmission case. Gently tap the seal into place using a suitable size socket. (Scheme 119)
- Install the new oil filter into position as noted during removal. Inspect the oil pan bolts and washers to determine if the conical washers are reversed. Reuse the oil pan bolts and washers if the conical washers are NOT reversed. Replace the oil pan bolts and washers if the conical washers are reversed. (Scheme 120)
- Install the new oil pan gasket to the oil pan sealing surface. Position the oil pan to the transmission case and support the oil pan.
- Install the oil pan bolts. Tighten the transmission oil pan bolts alternately and evenly to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Remove the transmission fluid check/fill plug. Fill the transmission with appropriate fluid through the check/fill plug hole until fluid begins to pour out, then install the check/fill plug hand-tight. See «RECOMMENDED FLUIDS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__recommended-fluids).
- Complete filling the transmission with fluid to the proper level. See «CHECKING FLUID LEVEL & CONDITION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-level-condition). Tighten the transmission fluid check/fill plug to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Inspect the oil pan gasket for leaks.
Scheme 115
Scheme 116
Scheme 117
Scheme 118
Scheme 119
Scheme 120
OIL COOLER FLUSHING
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.
| CAUTION | Flushing Solution (J 35944-22) is environmentally safe, yet powerful enough to cut through transmission fluid to dislodge any contaminants from the cooler. The safety precautions on the label regarding potential skin and eye irritations associated with prolonged exposure are typical precautions that apply to many similar cleaning solutions. It should be noted that according to General Motors, use of other non-approved fluids for cooler flushing can have an adverse reaction to the seals inside the transmission. |
Preparation
- After the repair or replacement transmission is installed in the vehicle, do not reconnect the oil cooler pipes.
- Remove the fill cap (9) on the Transmission Oil Cooler and Line Flusher (J 35944-A) and fill the flusher tank (4) with 20-21 oz. (0.6L) of flushing solution using the measuring cup (6). Do not overfill. 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 (9). (Scheme 121)
- Connect the flusher discharge hose (5) to the oil cooler return pipe (top connector) (may require J 35944-600). Clip the discharge hose (5) onto the oil drain container. 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 oil cooler feed pipe (bottom connector) (may require J 35944-600). (Scheme 122)
- 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. (Scheme 121)and (Scheme 122). Turn ON the water supply at the faucet.
Scheme 121
Scheme 122
Initial Flush
- 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. (Scheme 123) 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.
- 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. (Scheme 124) 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. (Scheme 121) Use the clip provided on the handle to hold the trigger (8) down. The discharge will foam vigorously when the solution is introduced into the water stream.
- 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.
- Release the trigger (8) and turn the flusher water supply valve (1) to the OFF position.
Scheme 123
Scheme 124
Back Flush
- Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe. This will allow the oil cooler and pipes to be back flushed. Repeat steps 2 and 3 of the INITIAL FLUSH procedure. Release the trigger (8) of the flusher and allow water only to rinse the oil cooler and pipes for one minute.
- Turn the flusher water supply valve (1) to the OFF position and turn OFF the water supply at the faucet. 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).
TRANSMISSION & OIL COOLER FLOW CHECK
- Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe (bottom connector) to the transmission and the return pipe (top connector) (may require J 35944-600) to the discharge hose (5). Clip the discharge hose (5) onto the empty oil drain container. (Scheme 124)
- Confirm the transmission is filled with automatic transmission fluid. See «CHECKING FLUID LEVEL & CONDITION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-level-condition). 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. If fluid flow is greater than 2 qts. (1.9L) in 30 seconds, go to next step. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, perform the following diagnosis: Disconnect the oil cooler feed line at the radiator. Connect the discharge hose (5) to the cooler feed line. Clip the discharge hose (5) to the empty oil drain container. (Scheme 124) 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. Do the following according to the flow rate: Insufficient feed flow: inspect the transmission. Sufficient feed flow: inspect the oil cooler return pipe and the oil cooler (and auxiliary cooler, if equipped).
- Remove the discharge hose (5), reconnect the cooler feed and return pipes to the transmission and refill the unit to the proper fluid level. Inspect the transmission oil cooler pipe connections at the radiator, the auxiliary cooler (if equipped) and the transmission for leaks.
ON-VEHICLE REPAIRS
Various components may be serviced without transmission removal. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION .
ADJUSTMENTS
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. |
PARK/NEUTRAL POSITION SWITCH
Note. Adjustment procedure is included with component removal and installation procedure. See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION.
SHIFT CONTROL CABLE
Raise and suitably support the vehicle. Shift the transmission into NEUTRAL. Using a flat-bladed screwdriver, carefully pry to release the transmission shift control cable adjustment lock. (Scheme 151) Check to be sure that the transmission floor shift control is in the NEUTRAL detent position. Check to be sure that the transmission is in the NEUTRAL detent position. Press to secure the transmission shift control cable adjustment lock. Lower the vehicle.
REMOVAL & INSTALLATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
| CAUTION | Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force, and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. |
Removal
- Raise and support the vehicle. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION.
- Remove the control valve body. See «VALVE BODY & PRESSURE SWITCHES»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing). Remove the accumulator cover retaining bolts. Remove the 1-2 accumulator cover assembly. (Scheme 125) Disassemble the 1-2 accumulator. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. (Scheme 126)
- Remove the 1-2 accumulator inner and outer springs. Inspect the 1-2 accumulator inner and outer springs for cracks. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. (Scheme 127) Inspect the 1-2 accumulator piston and cover for porosity, cracks, scoring, and nicks and scratches.
- Remove the spacer plate support retaining bolts. (Scheme 128) Use care not to drop the following items that will be removed along with the spacer plate: the number 1 check ball, the 3-4 accumulator spring and the 3-4 accumulator pin. Remove the spacer plate support.
- Remove the spacer plate-to-valve body gasket, the spacer plate and the spacer plate-to-transmission case gasket. (Scheme 129) Remove the 3-4 accumulator piston (2). (Scheme 130) Inspect the 3-4 accumulator spring for cracks. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. (Scheme 127) Inspect the 3-4 accumulator piston for porosity, cracks, scoring, and nicks and scratches.
Scheme 125
Scheme 126
Scheme 127
Scheme 128
Scheme 129
Scheme 130
Installation
- Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. (Scheme 127) Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with Transjel(tm) (J 36850). (Scheme 130) Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case.
- Install the locating pins (J 25025-B) (2, 3) to the transmission case. (Scheme 131) Install the spacer plate-to-transmission case gasket and the spacer plate-to-valve body gasket to the spacer plate; use Transjel(tm) (J 36850) in order to retain the gaskets to the spacer plate. (Scheme 129) 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. Ensure that the solenoid screens (1, 2) are in place on the spacer plate. Place the check ball (3) on the spacer plate in the location shown. Place the 3-4 accumulator spring (4) on the spacer plate. (Scheme 132) Install the spacer plate and related components to the transmission.
- Install the spacer plate support and the spacer plate support retaining bolts. (Scheme 128) Tighten the spacer plate support retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the check ball (1) has remained in the proper location. (Scheme 133) Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. (Scheme 127)
- Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover. (Scheme 126) Install the 1-2 accumulator cover and the accumulator cover retaining bolts. (Scheme 125) Tighten the accumulator cover retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Remove the guide pins from the transmission case.
- Install the control valve body. See «VALVE BODY & PRESSURE SWITCHES»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing). Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Lower the vehicle. Fill the transmission to the proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__lubrication).
Scheme 131
Scheme 132
Scheme 133
- Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY, SPACER PLATE & GASKETS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing).
- Disconnect the internal wiring harness electrical connectors from the following components: transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 control solenoid. (Scheme 165)
- Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 134) Remove the 1-2 and 2-3 shift solenoid retainers. Remove the 1-2 and 2-3 shift solenoids. (Scheme 135) Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 136)
Scheme 134
Scheme 135
Scheme 136
- Install the 3-2 control solenoid. Install the 3-2 control solenoid retainer. (Scheme 136) Install the 1-2 and 2-3 shift solenoids. Install the 1-2 and 2-3 shift solenoid retainers. (Scheme 135) Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt. (Scheme 134) Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
- Connect the internal wiring harness electrical connectors to the following components: transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 control solenoid. (Scheme 165) Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY, SPACER PLATE & GASKETS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing).
- Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Fill the transmission to the proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__lubrication).
- Position the front wheels straight ahead, and remove the ignition key to lock the steering column. Disconnect the negative battery cable. Drain the cooling system. Raise and suitably support the vehicle. Place a drain pan under the vehicle to catch any fluid.
- Reposition the plastic retainer, in order to gain access to the lower Transmission Oil Cooler (TOC) connection. Using Transmission Cooler Quick Disconnect (J 44827), disconnect the lower TOC line from the oil cooler. Lower the vehicle; leave the vehicle on the hoist. Reposition the plastic retainer, in order to gain access to the upper TOC connection. Using Transmission Cooler Quick Disconnect (J 44827), disconnect the upper TOC line from the oil cooler. Remove the air cleaner assembly.
- Remove the upper and lower radiator support. Recover the refrigerant from the A/C system. See GENERAL SERVICING in HEATING & AIR CONDITIONING. Remove the front evaporator tube to condenser bolt. (Scheme 137) Disconnect the front evaporator tube from the condenser.
- Using a back-up wrench on the condenser fitting (2), loosen the compressor hose fitting (1) from the condenser. (Scheme 138) Disconnect the compressor hose from the condenser. (Scheme 139) Discard the O-ring seal, and cap or tape the compressor hose and condenser openings. Using Spring Hose Clamp Pliers (J 38185), release and reposition the coolant surge tank upper hose clamp away from the radiator inlet. Separate the surge tank upper hose from the radiator inlet.
- Using Spring Hose Clamp Pliers (J 38185), release and reposition the radiator inlet hose clamp away from the radiator inlet. Separate the radiator inlet hose from the radiator inlet. Using Spring Hose Clamp Pliers (J 38185), release and reposition the radiator outlet hose clamp away from the radiator outlet. Separate the radiator outlet hose from the radiator outlet. Carefully pivot the A/C condenser with the radiator forward, and tie off to support the assembly.
- Remove the steering column intermediate shaft lower coupling shield. Match-mark the intermediate shaft lower coupling to the Power Steering (PS) gear to ensure correct orientation upon installation. Remove the intermediate shaft lower coupling bolt. Disconnect the intermediate shaft lower coupling from the PS gear. Slide the intermediate shaft lower coupling off of the PS gear steering shaft. (Scheme 140)
- Remove the PS cooler retaining bolts. (Scheme 141) Remove the Brake Pressure Modulator Valve (BPMV) bracket. See appropriate ANTI-LOCK article in BRAKES. Remove the PS gear mounting bolts and nuts. Release the PS gear and cooler from the front suspension crossmember, then pull the gear and cooler forward. (Scheme 142)
- Remove the A/C compressor bracket. Remove the generator. See appropriate GENERATORS & REGULATORS article in STARTING & CHARGING SYSTEMS. Install the Engine Support Fixture (J 41803) and the Universal Engine Support Fixture (J 28467-B) in order to support the engine. Remove the right hand engine mount (and bracket).
- Remove the TOC front pipe front clip. (Scheme 143) Raise the vehicle. Remove the TOC front pipe front retaining clamp bolt and retaining clamp. (Scheme 144) Remove the TOC front pipe rear retaining clamp bolt and retaining clamp. (Scheme 145) Disconnect the TOC front pipe fittings from the junction fittings at the engine flywheel housing, then cap the pipe fittings and plug the junction fittings to prevent contamination. Lower the vehicle; leave the vehicle slightly above the ground. Finesse the TOC front pipes out of the vehicle (through the top).
Scheme 137
Scheme 138
Scheme 139
Scheme 140
Scheme 141
Scheme 142
Scheme 143
Scheme 144
Scheme 145
- Install the TOC front pipes to the vehicle (through the top of the vehicle). Finesse the pipes into position. Raise the vehicle. Remove the caps from the rear of the TOC front pipes and remove the plugs from the junction fittings at the engine flywheel housing.
- ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC front upper and lower pipe fittings to the junction fittings at the engine flywheel housing. Tighten the transmission oil cooler front upper and lower pipe fittings to the junction at the engine flywheel housing to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
- Install the TOC front pipe rear retaining clamp and bolt. (Scheme 145) Tighten the transmission oil cooler front pipe rear retaining clamp bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the TOC front pipe front retaining clamp and bolt. (Scheme 144) Tighten the transmission oil cooler front pipe front retaining clamp bolt to specification.
- Install the TOC front pipe front clip. (Scheme 143) Install the right hand engine mount (and bracket). Lower the vehicle; leave the vehicle on the hoist. Remove the engine support fixtures.
- Install the generator. Install the A/C compressor bracket. Position the PS gear and cooler to the front suspension crossmember. (Scheme 141)and (Scheme 142). Install the BPMV bracket.
- Install the PS gear mounting bolts and nuts. Tighten the power steering gear mounting nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the PS cooler retaining bolts. Tighten the power steering cooler retaining bolts to specification.
- Connect the intermediate shaft lower coupling to the PS gear; be sure that the intermediate shaft and the PS gear steering shaft are orientated as marked prior to disconnecting them. Slide the intermediate shaft lower coupling onto the PS gear steering shaft. Install the intermediate shaft lower coupling bolt. (Scheme 140) Tighten the steering gear intermediate shaft lower coupling bolt to specification.
- Install the intermediate shaft lower coupling shield. Lower the vehicle. Remove the tie-off retainer and carefully pivot the AC condenser and the radiator back into position. Install the radiator outlet hose to the radiator outlet. Position the radiator outlet hose clamp onto the radiator outlet.
- Install the radiator inlet hose to the radiator inlet. Position the radiator inlet hose clamp onto the radiator inlet. Install the surge tank upper hose to the radiator inlet. Position the coolant surge tank upper hose clamp onto the radiator inlet.
- Install the compressor hose to the condenser. (Scheme 139) Using a back-up wrench on the condenser fitting (2), tighten the compressor hose fitting (1) to the condenser. (Scheme 138) Tighten the fitting to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Connect the front evaporator tube to the condenser. Install the front evaporator tube-to-condenser bolt. (Scheme 137) Tighten the fitting to specification.
- Install the upper and lower radiator support. Install the air cleaner assembly. Connect the upper TOC line to the oil cooler using the following steps: Push the TOC pipe into the quick connect fitting, until a click is heard. Tug gently in the TOC line to ensure a proper connection. Position the plastic retainer over the connection.
- Raise the vehicle. Connect the lower TOC line to the oil cooler using the following steps: Push the TOC pipe into the quick connect fitting, until a click is heard. Tug gently in the TOC line to ensure a proper connection. Position the plastic retainer over the connection.
- Lower the vehicle. Connect the negative battery cable. Fill the cooling system. Recharge the A/C system. Check the transmission fluid level. See «CHECKING FLUID LEVEL & CONDITION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-level-condition) under LUBRICATION. Add if necessary.
- Raise and suitably support the vehicle. Remove the catalytic converter. Remove the right side muffler.
- Remove the driveline tunnel closeout panel. (Scheme 146) Disconnect the transmission oil cooler (TOC) rear upper and lower pipe fittings from the junction fittings at the engine flywheel housing, then cap the pipes and plug the junction fittings to prevent contamination. (Scheme 145)
- Disconnect the TOC rear upper and lower pipe fittings from the transmission fittings, then cap the pipes and plug the transmission fittings to prevent contamination. (Scheme 147) Remove the TOC rear pipe rear clip. (Scheme 148)
- Remove the TOC rear pipe middle clip. Remove the TOC rear pipe front and rear clamp bolts and clamps. (Scheme 149) Remove the TOC rear pipes from the vehicle.
Scheme 146
Scheme 147
Scheme 148
Scheme 149
- Install the transmission oil cooler (TOC) rear pipes into position. Install the TOC rear pipe front and rear retaining clamps and bolts. (Scheme 149) Tighten the transmission oil cooler rear pipe front and rear retaining clamp bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the TOC rear pipe middle clip.
- Install the TOC rear pipe rear clip. (Scheme 148) Remove the caps from the rear of the TOC rear pipes and remove the plugs from the transmission fittings. ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC rear upper and lower pipe fittings to the transmission fittings. (Scheme 147) Tighten the transmission oil cooler rear upper and lower pipe fittings to the transmission fittings to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
- ALIGN and HAND-START, then tighten ONLY by hand to seat the TOC rear upper and lower pipe fittings to the junction fittings at the engine flywheel housing. (Scheme 145) Tighten the transmission oil cooler rear upper and lower pipe fittings to the junction fittings at the engine flywheel housing to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
- Install the driveline tunnel closeout panel. (Scheme 146) Install the right side muffler. Install the catalytic converter. Check the transmission fluid level. See «CHECKING FLUID LEVEL & CONDITION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__checking-fluid-level-condition) under LUBRICATION. Add if necessary. Lower the vehicle.
| CAUTION | Use care to not suddenly jerk the shift control cable during disassembly, as the shift control cable rod end guide tubes are EXTREMELY INFLEXIBLE and capable of only a SLIGHT bend. |
- Raise and suitably support the vehicle. Remove the intermediate exhaust pipe and allow the LH muffler assembly to hang down out of the way. Shift the transmission into NEUTRAL. Remove the nuts retaining the transmission shift control cable bracket to the transmission. (Scheme 150)
- CAREFULLY release the shift control cable end clip from the transmission shift lever stud. (Scheme 151) Reposition the transmission shift cable and bracket. Disconnect the park/neutral position switch electrical connectors. (Scheme 152)
- Using a wrench on the transmission manual shaft wrench flats (in order to keep the shaft from turning), remove the range selector (shift) lever retaining nut.
- Remove the range selector (shift) lever. (Scheme 153) Check that the transmission is still in NEUTRAL. Remove the park/neutral position switch mounting bolts. Slide the switch off of the manual shaft. (Scheme 154)
Scheme 150
Scheme 151
Scheme 152
Scheme 153
Scheme 154
Note. Do not remove the Park/Neutral Position Switch Aligner (J 41364-A) from the park/neutral position switch until instructed.
- Install the Park/Neutral Position Switch Aligner (J 41364-A) to the park/neutral position switch. Align the two lower slots on the switch with the two lower tabs on the aligner tool. (Scheme 155)
- Rotate the aligner tool until the upper pin on the aligner tool is lined up with the notch on the top of the switch. (Scheme 155) Check that the transmission is still in NEUTRAL.
- Install the park/neutral position switch to the transmission manual shaft. Align the flats in the switch hub with the flats on the manual shaft. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission case.
- Install the park/neutral position switch mounting bolts. Tighten the park/neutral position switch mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Remove the aligner tool from the switch. Install the transmission range selector (shift) lever onto the transmission manual shaft. Be sure to install the shift lever in an upright orientation.
- Using a wrench on the transmission manual shaft wrench flats (in order to keep the shaft from turning), install the range selector (shift) lever retaining nut. Tighten the transmission range selector lever nut to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Connect the park/neutral position switch electrical connectors.
- Install the transmission shift control cable and bracket into position. Align the shift control cable end to the transmission shift lever stud. CAREFULLY secure the shift control cable end clip to the transmission shift lever stud.
- Install the nuts retaining the transmission shift control cable bracket to the transmission. Tighten the transmission shift control cable bracket retaining nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the intermediate exhaust pipe. Shift the transmission into PARK. Lower the vehicle.
Scheme 155
- Raise and support the vehicle. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. (Scheme 156) Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
- Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). (Scheme 157) Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). Remove the pressure regulator valve (1).
Scheme 156
Scheme 157
- Install the pressure regulator valve (1). Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (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 157)
- Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. (Scheme 156) Install the transmission oil filter and pan. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION.
- Lower the vehicle. Fill the transmission to the proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__lubrication).
- Raise and suitably support the vehicle. Shift the floor shift control to NEUTRAL. If replacing a damaged cable, be sure that BOTH the floor shift control and the transmission are in NEUTRAL. Remove the catalytic converter assembly. Remove the driveline tunnel closeout panel.
- Using a large flat-bladed screwdriver, CAREFULLY release the shift control cable end clip from the floor shift control arm stud. (Scheme 158)
- Remove the shift control cable from the driveline tunnel bracket as follows: Using a flat-bladed screwdriver, pry the cable retaining staple clip from the cable. Depress the cable retaining tabs. While depressing the tabs, push the tabs through the hole in the driveline tunnel bracket. Slide the cable out of the bracket slot.
- Remove the nuts retaining the shift control cable bracket to the transmission. (Scheme 150) Reposition the cable and cable bracket away from the studs. CAREFULLY release the shift control cable end clip from the transmission shift lever stud. (Scheme 151) Remove the shift control cable and bracket.
- Remove the shift control cable bracket from the shift control cable (if necessary) as follows: Using a flat-bladed screwdriver, pry the shift cable retaining staple clip from the cable. Depress the shift cable retaining tabs. While depressing the tabs, push the tabs through the hole in the shift cable bracket. Slide the cable out of the bracket slot. (Scheme 159)
Scheme 158
Scheme 159
- Install the shift control cable bracket to the shift control cable (if removed) as follows: Slide the smaller diameter portion of the cable into the slot in the shift cable bracket. Push the tabs through the hole in the bracket to lock the cable in place. Insert the shift cable retaining staple clip between the shift cable retaining tabs. Press the staple clip firmly to secure.
- Position and install the shift control cable to the driveline tunnel bracket as follows: Slide the smaller diameter portion of the shift cable into the slot in the driveline tunnel bracket. Push the shift cable retaining tabs through the hole in the bracket to lock the cable in place. Insert the shift cable retaining staple clip between the shift cable retaining tabs. Press the staple clip firmly to secure.
- Align the shift control cable end to the floor shift control arm stud.
- CAREFULLY secure the shift control cable end clip to the floor shift control arm stud. Install the shift control cable bracket to the transmission studs.
- Install the nuts retaining the shift control cable bracket to the transmission. Tighten the transmission shift control cable bracket retaining nuts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Check to be sure that BOTH the floor shift control and the transmission are in NEUTRAL. Align the shift control cable end to the transmission shift lever stud.
- CAREFULLY secure the shift control cable end clip to the transmission shift lever stud. If installing a NEW transmission shift control cable, remove the shipping guard from the adjuster lock. (Scheme 160)
- If installing a NEW transmission shift control cable, depress the shift control cable adjuster lock. Lower the vehicle; leave the vehicle on the hoist. Verify that the shift control cable is operating smoothly as follows: Firmly apply the parking brake. Turn the ignition switch to ON; DO NOT start the engine. Apply the regular brakes. Shift from NEUTRAL to FIRST, then shift from FIRST to SECOND, then DRIVE and so on; pause for one second in each detent position. Take note of an audible sound from the transmission shift lever each time a shift detent is selected. Shift from PARK directly to FIRST. Repeat steps "D" and "E" an additional 2 times. If any binding is felt during this check, or if no audible sound was produced from the transmission shift lever, inspect the shift control cable for damage (at either end of the cable). Shift the floor shift control into PARK. Release the regular brakes. Turn the ignition switch OFF. Release the parking brake.
- Raise and support the vehicle. Install the driveline tunnel closeout panel. Install the catalytic converter assembly. Test drive the vehicle in an area with little traffic; ensure that the transmission will shift smoothly into and maintain each detent position.
Scheme 160
- Raise and support the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 161) Depress both tabs on the connector and pull straight up; do not pry the connector.
- Remove the 1-2 accumulator assembly. Do not remove the spacer plate. See «ACCUMULATOR ASSEMBLY, SPACER PLATE & GASKETS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing). Disconnect the internal wiring harness electrical connectors from the following components: transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 control solenoid. (Scheme 165)
- Remove the TCC PWM solenoid retainer. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts. (Scheme 167) Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 134)
- Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 162) Using Seal Protector Retainer Installer (J 28458), release the pass-through electrical connector from the transmission case. Use the small end of the tool over the top of the connector. Twist in order to release the 4 tabs retaining the connector. Pull the harness connector down through the transmission case. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case. (Scheme 163)and (Scheme 169).
- Inspect the TCC solenoid and wiring harness assembly for damage, cracked connectors, exposed wires and loose pins.
Scheme 161
Scheme 162
Scheme 163
- 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. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Tighten the TCC solenoid retaining bolts to specification.
- Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt. (Scheme 134) Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the TCC PWM solenoid to the control valve body. Install the TCC PWM solenoid retainer. (Scheme 167)
- Connect the internal wiring harness electrical connectors to the following components: transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 control solenoid. (Scheme 165) Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY, SPACER PLATE & GASKETS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing).
- 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 161) Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Lower the vehicle. Fill the transmission to the proper level with appropriate fluid. See «LUBRICATION»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__lubrication).
- Ensure that removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1). The pressure control solenoid (2). The internal wiring harness (3). The 2-3 shift solenoid (4). The 1-2 shift solenoid (5). The transmission fluid pressure manual valve position switch (6). The 3-2 shift solenoid (7). The torque converter clutch pulse width modulation (TCC PWM) solenoid (8). Refer to illustration for component identification. (Scheme 164)
- Remove the fluid level indicator. Raise and support the vehicle. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION.
- Disconnect the internal wiring harness electrical connectors from the following components: transmission fluid pressure manual valve position switch, 1-2 shift solenoid, 2-3 shift solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift solenoid. (Scheme 165)
- Remove the fluid indicator stop bracket bolt (2). Remove the fluid indicator bracket (1). (Scheme 166) 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. (Scheme 167) Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts.
- Remove the TCC solenoid retaining bolts. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body. (Scheme 168)and (Scheme 169). Reposition the harness to the side of the transmission case.
- Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. Remove the transmission fluid pressure switch. Inspect the transmission fluid pressure switch for damage or debris. (Scheme 170)
- Remove the manual detent spring retaining bolt. Remove the manual detent spring. Inspect the manual detent spring for cracks or damage.
- 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 171) If disassembly, cleaning, inspection and assembly of the control valve body is necessary, see appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS.
Scheme 164
Scheme 165
Scheme 166
Scheme 167
Scheme 168
Scheme 169
Scheme 170
Scheme 171
- Install the check balls in the valve body. (Scheme 172) Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 171) Verify that the manual valve link is installed properly to the inside detent lever and the manual valve. (Scheme 173) Install one bolt (M6 X 1.0 X 47.5) hand-tight in the center of the valve body to hold it in place.
- Do not install the transmission fluid indicator stop bracket and bolt at this time. Install, but do not tighten, the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the illustration. (Scheme 174)
- Install the manual detent spring. Install, but do not tighten, the manual detent spring retaining bolt. Install the transmission fluid pressure switch. Install, but do not tighten, the control valve body bolts which retain the transmission fluid pressure switch to the control valve body.
- Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. (Scheme 174) Tighten the control valve body bolts (in sequence) to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Ensure that the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification.
- 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/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications). Install the internal wiring harness to the valve body. (Scheme 169) The internal wiring harness has a tab (1) on the edge of the conduit. (Scheme 175)
- Place the tab between the valve body and the pressure switch in the location shown (2). (Scheme 176) Press the harness into position on the valve body bolt bosses (1, 3).
- Install the TCC PWM solenoid (1) to the control valve body. Install the TCC PWM solenoid retainer (2). (Scheme 167) Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 166) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__torque-specifications).
- Connect the internal wiring harness electrical connectors to the following components: transmission fluid pressure manual valve position switch, 1-2 shift solenoid, 2-3 shift solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift solenoid. (Scheme 165)
- Install the transmission oil pan and filter. See «DRAINING & REFILLING»(/chevrolet/corvette/c5-1997-2004/remont/automatic-trans/#automatic-transmission-servicing__draining-refilling) under LUBRICATION. Lower the vehicle. Add transmission fluid to obtain the proper fluid level.
Scheme 172
Scheme 173
Scheme 174
Scheme 175
Scheme 176
- Raise and suitably support the vehicle. Release the transmission vent hose from the lower retaining clip. (Scheme 177)
- Remove the transmission vent hose from the transmission vent tube.
- To install, connect the transmission vent hose to the transmission vent tube. Orient the transmission vent hose check valve as noted prior to removal. Secure the transmission vent hose to the lower retaining clip. Lower the vehicle.
Scheme 177
TORQUE SPECIFICATIONS
| Application | Ft. Lbs. (N.m) |
| Compressor Hose-To-Condenser Fitting | 17 (24) |
| Front Evaporator Tube-To-Condenser Bolt | 20 (27) |
| Oil Check/Fill Plug | 22 (30) |
| Oil Cooler Line-To-Flywheel Housing Fitting | 20 (27) |
| Oil Cooler Line-To-Transmission Fitting | 26 (35) |
| PNP Switch Mounting Bolt | 20 (27) |
| Power Steering Gear Mounting Nut | 74 (100) |
| Shift Control Cable Bracket Retaining Nut | 15 (20) |
| Steering Gear Intermediate Shaft Coupling Bolt | 25 (34) |
| Transmission Range Selector Lever Nut | 15 (20) |
| INCH Lbs. (N.m) |
| Accumulator Cover Retaining Bolt | 97 (11) |
| Front Oil Cooler Line Front Clamp Bolt | 106 (12) |
| Front Oil Cooler Line Rear Clamp Bolt | 19 (2.2) |
| Manual Detent Spring Bolt | 97 (11) |
| Oil Pan Bolt | 97 (11) |
| Power Steering Cooler Bolt | 97 (11) |
| Pressure Control Solenoid Retaining Bolt | 97 (11) |
| Rear Oil Cooler Line Front & Rear Clamp Bolts | 106 (12) |
| Spacer Plate Support Retaining Bolt | 97 (11) |
| TCC Solenoid Retaining Bolt | 97 (11) |
| Transmission Fluid Indicator Stop Bracket Bolt | 97 (11) |
| Valve Body-To-Transmission Bolt | 97 (11) |