Automatic Transmission - 4L60-E/4L65-E - Servicing: Removal & Installation Chevrolet Silverado 1500 HD

REMOVAL & INSTALLATION

Removal

1. Remove the transmission filter.
2. Remove the control valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-154009-S14273977072003050100000).
3. Remove the accumulator cover bolts. (Scheme 143)
4. Remove the 1-2 accumulator cover.
5. Disassemble the 1-2 accumulator as follows: Blow compressed air into the 1-2 accumulator cover in order to remove the 1-2 accumulator piston. (Scheme 144) Remove the 1-2 accumulator inner and outer springs.
6. Inspect the 1-2 accumulator inner and outer springs for cracks.
7. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. (Scheme 145)
8. Inspect the 1-2 accumulator piston for the following defects: Porosity. Cracks. Scoring. Nicks and scratches.
9. Inspect the 1-2 accumulator cover for the following defects: Porosity. Cracks. Scoring. Nicks and scratches. (Scheme 146)
10. Remove the spacer plate support bolts. (Scheme 147) NOTE: Use care not to drop the number one checkball, the 3-4 accumulator spring and the 3-4 accumulator pin.
11. Remove the spacer plate support.
12. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. (Scheme 148)
13. Remove the 3-4 accumulator piston. (Scheme 149)
14. Inspect the 3-4 accumulator spring for cracks.
15. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. (Scheme 145)
16. Inspect the 3-4 accumulator piston for the following defects: Porosity. Cracks. Scoring. Nicks and scratches.

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Installation

1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. (Scheme 145)
2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with Transjel(R) lubricant. (Scheme 150)
3. Install the 3-4 accumulator piston onto the pin in the transmission case. (Scheme 149) Ensure that the 3-4 accumulator piston legs face away from the transmission case.
4. Install the pump and valve body alignment pin set (2, 3) to the transmission case. (Scheme 150)
5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use Transjel(R) lubricant in order to retain the gaskets to the spacer plate. (Scheme 151) The case gasket is identified by a "C". Be sure to place the case gasket on the transmission case side of the spacer plate. The valve body gasket is identified by a "V". Be sure to place the valve body gasket on the valve body side of the spacer plate.
6. Ensure that the solenoid screens (1 and 2) are in place on the spacer plate.
7. Place the checkball (3) on the spacer plate in the location shown.
8. Place the 3-4 accumulator spring (4) on the spacer plate.
9. Install the spacer plate and related components to the transmission.
10. Install the spacer plate support and the spacer plate support bolts. (Scheme 147) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. (Scheme 152)
12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. (Scheme 145)
13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. (Scheme 153)
14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover.
15. Install the 1-2 accumulator cover and the accumulator cover bolts. (Scheme 143) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
16. Remove the pump and valve body alignment pin set from the transmission case.
17. Install the valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-154009-S14273977072003050100000).
18. Install the transmission filter.

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Remove the front grill assembly.
2. Place a drain pan under the vehicle.
3. Disconnect the transmission oil cooler lines from the auxiliary cooler.
4. Remove the auxiliary oil cooler bolts (1) and push pins (2). (Scheme 154)
5. Remove the auxiliary oil cooler from the vehicle.

Scheme 154

1. Install the auxiliary oil cooler to the vehicle.
2. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. (Scheme 154) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
3. Connect the transmission oil cooler lines to the auxiliary cooler.
4. Install the front grill assembly.

1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION. NOTE: DO NOT remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY»(ref-154009-S14743688422003050100000).
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. (Scheme 155) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid. 3-2 shift control solenoid.
4. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 156)
5. Remove the 1-2 and 2-3 shift control solenoid retainers. Remove the 1-2 and 2-3 shift control solenoids. (Scheme 157)
6. Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 158)

Scheme 155

Scheme 156

Scheme 157

Scheme 158

1. Install the 3-2 control solenoid. Install the 3-2 control solenoid retainer. Install the 1-2 and 2-3 shift control solenoids. (Scheme 158)
2. Install the 1-2 and 2-3 shift control solenoid retainers. Install the pressure control solenoid. Ensure the electrical tabs are facing outboard. (Scheme 157)
3. Install the pressure control solenoid retainer and retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
4. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. (Scheme 155) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 control solenoid.
5. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(ref-154009-S14743688422003050100000).
6. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.
7. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154009-S42434605272003050100000).

1. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
2. Remove the transmission mount.
3. Support the transmission with a transmission jack.
4. Place a drain pan under the vehicle.
5. Remove the case extension bolts (1). (Scheme 159)
6. Remove the case extension (2).
7. Remove and discard the case extension "O" ring seal (3).

Scheme 159

1. Install a new case extension "O" ring seal (3). (Scheme 159)
2. Install the case extension (2).
3. Install the case extension bolts (1). Tighten the case extension bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
4. Install the transmission mount.
5. Remove the drain pan and the transmission jack.
6. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
7. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154009-S42434605272003050100000).

1. Place a drain pan under the vehicle.
2. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
3. Remove the rear extension oil seal. (Scheme 160)
4. Inspect the case extension housing for damage. Replace the extension housing if necessary.

Scheme 160

1. Lubricate the inside diameter of the NEW seal with Transjel(R) lubricant.
2. Install the new seal using rear extension seal installer and a soft faced mallet. (Scheme 161)
3. Remove the drain pan.
4. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
5. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154009-S42434605272003050100000).

Scheme 161

1. Remove the transmission oil level indicator.
2. Raise and suitably support the vehicle.
3. Support the transmission using a suitable jack.
4. Remove the transmission mount nut. (Scheme 162)
5. Remove the transmission crossmember bolts/nuts. (Scheme 163)
6. Remove the transmission crossmember.
7. Loosen the left exhaust pipe nuts. (Scheme 164)
8. Loosen the right exhaust pipe nuts. (Scheme 165)
9. Remove the insulator nuts and insulator from the bracket. (Scheme 166)
10. Remove the exhaust pipe hanger bracket bolts and bracket.
11. Lower the transmission slightly.
12. Disconnect the transmission oil cooler lines. (Scheme 167)
13. Plug the transmission oil cooler line fittings.
14. Remove the indicator tube nut. (Scheme 168)
15. Remove the oil level indicator tube. (Scheme 169)
16. Remove the seal from the transmission, if necessary.

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

1. Install a NEW seal to the indicator tube.
2. Install the oil level indicator tube.
3. Install the indicator tube nut. (Scheme 168) Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
4. Remove the plugs from the transmission oil cooler line fittings. (Scheme 167)
5. Connect the transmission oil cooler lines.
6. Install the exhaust pipe hanger bracket and bolts. (Scheme 166) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
7. Instal the insulator and nuts to the bracket. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
8. Tighten the right exhaust pipe nuts. (Scheme 165) Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
9. Tighten the left exhaust pipe nuts. (Scheme 164) Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
10. Install the transmission crossmember. (Scheme 163)
11. Install the transmission crossmember bolts/nuts. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
12. Install the transmission mount nut. (Scheme 162) Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
13. Remove the support from the transmission.
14. Lower the vehicle.
15. Install the transmission oil level indicator.
16. Fill transmission to proper level with appropriate fluid. See «LUBRICATION»(ref-154009-S42434605272003050100000).

1. Remove the front grill assembly.
2. Remove the transmission fluid cooler hose from the auxiliary oil cooler. (Scheme 170) See «OIL COOLER LINE QUICK CONNECT FITTING»(ref-154009-S00649764822003050200000).
3. Remove the transmission fluid cooler hose from the radiator. See «OIL COOLER LINE QUICK CONNECT FITTING»(ref-154009-S00649764822003050200000).
4. Raise the vehicle.
5. Remove the engine protection shield.
6. Remove the cooling lines from the transmission. (Scheme 167) See «OIL COOLER LINE QUICK CONNECT FITTING»(ref-154009-S00649764822003050200000).
7. Remove the oil cooling lines from the vehicle.

Scheme 170

1. Install the transmission oil cooler lines to the vehicle.
2. Install the cooling lines to the transmission. (Scheme 167) See «OIL COOLER LINE QUICK CONNECT FITTING»(ref-154009-S00649764822003050200000).
3. Install the engine protection shield.
4. Lower the vehicle.
5. Install the transmission fluid cooler hose to the radiator. (Scheme 170) See «OIL COOLER LINE QUICK CONNECT FITTING»(ref-154009-S00649764822003050200000).
6. Install the transmission fluid cooler hose to the Auxiliary oil cooler. See «OIL COOLER LINE QUICK CONNECT FITTING»(ref-154009-S00649764822003050200000).
7. Install the front grill assembly.

1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 2 in (5 cm).
2. 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. (Scheme 171)
3. Remove the retaining ring from the quick connect fitting.
4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting. (Scheme 172)

Scheme 171

Scheme 172

Note. DO NOT reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. DO NOT reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings.

1. Install a new retaining ring into the quick connect fitting using the following procedure: Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 173) 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 174) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 175) 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 176)
2. Install the cooler line into the quick connect fitting. (Scheme 177)
3. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
4. DO NOT use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 178)
5. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
6. 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. (Scheme 179)
7. Ensure that the plastic cap is fully seated against the fitting.
8. Ensure that no gap is present between the cap and the fitting. (Scheme 180)
9. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. (Scheme 179)
10. A hidden yellow identification band indicates proper joint seating. (Scheme 181)
11. Fill transmission to proper level with appropriate fluid. See «LUBRICATION»(ref-154009-S42434605272003050100000).

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

1. Apply the Parking brake.
2. Shift the transmission into Neutral.
3. If equipped with 4WD, remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
4. Raise and suitably support the vehicle.
5. Disconnect the Park/Neutral Position (PNP) switch electrical connectors (2). (Scheme 182)
6. Remove the manual shaft lever nut. (Scheme 183)
7. Remove the transmission control lever from the manual shaft.
8. Remove the PNP switch bolts.
9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs.

Scheme 182

Scheme 183

1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. (Scheme 182)
2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. NOTE: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary.
3. Install the PNP switch bolts finger tight.
4. Install park/neutral position switch aligner onto the PNP switch. (Scheme 184) 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.
5. 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 to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
6. Remove the park/neutral position switch aligner from the switch. If installing a new switch, remove the positive assurance bracket at this time.
7. Install the transmission control lever to the manual shaft with the nut. (Scheme 182) Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
8. Connect the PNP switch electrical connectors (2). (Scheme 182)
9. If equipped with 4WD, install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
10. Lower the vehicle.
11. Check the switch for proper operation. The engine must start in the Park (P) or Neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch.

Scheme 184

1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.
2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. (Scheme 185)
3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). (Scheme 186)
5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
6. Remove the pressure regulator valve (1).

Scheme 185

Scheme 186

1. Install the pressure regulator valve (1). (Scheme 186)
2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5).
4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover.
5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot.
6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. (Scheme 185)
7. Install the transmission oil filter and pan. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.

1. Apply the Parking brake.
2. Place the transmission into Neutral.
3. Raise and support the vehicle.
4. Remove the retainer that secures the cable to the bracket. (Scheme 187)
5. Depress the tangs and remove the cable from the bracket.
6. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission. (Scheme 188)
7. Remove the transmission range selector cable bracket.

Scheme 187

Scheme 188

1. Install the shift cable bracket to the vehicle.
2. Install the shift cable bracket bolts (1). (Scheme 188) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
3. Align and install the cable to the bracket. (Scheme 187)
4. Install the retainer that secures the cable to the bracket.
5. Lower the vehicle.
6. Check the vehicle for proper operation. If cable adjustment is necessary, see «SHIFT CABLE»(ref-154009-S23952871182003050100000) under ADJUSTMENTS.

1. Position the steering column shift lever to the Park position.
2. Remove the instrument panel knee bolster.
3. Remove the driver's seat.
4. Pull back the carpet and insulation around the driver's area.
5. Remove the retainer securing the cable to the steering column. (Scheme 189)
6. Remove the cable end from the steering column ball stud. (Scheme 190)
7. Depress the tangs and remove the cable from the steering column bracket.
8. Remove the bolt securing the cable support to the brace. (Scheme 191) NOTE: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support.
9. Remove the range selector cable from the support. (Scheme 192)
10. Remove the cable grommet from the floor panel. (Scheme 193)
11. Raise and suitably support the vehicle.
12. Remove the clips on the cable from the floor panel reinforcement. (Scheme 194)
13. Ensure the transmission manual shaft is positioned in mechanical Park.
14. Remove the retainer that secures the cable to the bracket. (Scheme 187)
15. Remove the cable clip on the transfer case, if equipped.
16. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). (Scheme 195)
17. Depress the tangs and remove the cable from the bracket.
18. Lower the vehicle and ensure that the steering column shift lever is still in the Park position.

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

1. Ensure that the transmission manual shaft lever is in the mechanical Park position.
2. Align and install the cable to the bracket.
3. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). (Scheme 195)
4. Install the cable clip on the transfer case, if equipped.
5. Install the retainer that secures the cable to the bracket. (Scheme 187)
6. Install the clips on the cable to the floor panel reinforcement. (Scheme 194)
7. Lower the vehicle.
8. Install the cable grommet to the floor panel. (Scheme 193) NOTE: Avoid unnecessary twisting/bending of the range selector cable when installing the cable to the support.
9. Install the range selector cable to the support. (Scheme 192)
10. Install the bolt securing the cable support to the brace. (Scheme 191) Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
11. Install the cable to the steering column bracket. (Scheme 190)
12. Ensure the tangs fully seat (snap) into the steering column bracket.
13. Install the cable end to the steering column ball stud.
14. Install the retainer securing the cable to the steering column. (Scheme 189)
15. Position the carpet and insulation around the driver's area.
16. Install the driver's seat.
17. Install the instrument panel knee bolster.
18. Test the transmission for proper shift operation.
19. If all of the gear positions cannot be achieved, adjust the cable.

1. Raise and support the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.
2. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 196) Depress both tabs on the connector and pull straight up, DO NOT pry the connector.
3. Remove the 1-2 accumulator assembly. See «ACCUMULATOR ASSEMBLY»(ref-154009-S14743688422003050100000).
4. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. (Scheme 155) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
5. Remove the TCC PWM solenoid retainer. (Scheme 197)
6. Remove the TCC PWM solenoid to access one of the TCC solenoid retaining bolts.
7. Remove the pressure control solenoid retainer.
8. Remove the pressure control solenoid. (Scheme 156)
9. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 198)
10. Using the seal protector retainer installer, release the pass-through electrical connector from the transmission case. (Scheme 199) Use the small end of the seal protector retainer installer over the top of the connector. Twist to release the 4 tabs retaining the connector. Pull the harness connector down through the transmission case.
11. Remove the TCC solenoid (with "O" ring seal) and wiring harness.
12. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage. (Scheme 200) Cracked connectors. Exposed wires. Loose pins.

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

1. Install the wiring harness and TCC solenoid assembly with a new "O" ring seal to the transmission. (Scheme 199)
2. Install the pass-through electrical connector to the transmission case.
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. (Scheme 198) Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000). Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
4. Install the pressure control solenoid. (Scheme 156) Ensure the electrical tabs are facing outboard.
5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
6. Install the TCC PWM solenoid to the control valve body. (Scheme 197)
7. Install the TCC PWM solenoid retainer.
8. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. (Scheme 155) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
9. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(ref-154009-S14743688422003050100000).
10. 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 196)
11. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.

1. Ensure removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission. (Scheme 201) Torque Converter Clutch Solenoid (1). Pressure Control Solenoid (2). Internal Wiring Harness (3). 2-3 Shift Solenoid (4). 1-2 Shift Solenoid (5). Transmission Fluid Pressure Manual Valve Position Switch (6). 3-2 Shift Solenoid (7). Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid (8).
2. Remove the fluid level indicator.
3. Remove the filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.
4. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure manual valve position switch. (Scheme 155) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid. Bracket bolt.
5. Remove the fluid indicator stop bracket bolt. (Scheme 202)
6. Remove the fluid indicator bracket (1).
7. 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.
8. Remove the TCC PWM solenoid (1) to access the TCC solenoid retaining bolts. (Scheme 197)
9. Remove the TCC solenoid bolts. (Scheme 203)
10. Remove the TCC solenoid (with "O" ring seal) and wiring harness from the control valve body.
11. Reposition the harness to the side of the transmission case. (Scheme 199)
12. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 204)
13. Remove the transmission fluid pressure switch.
14. Inspect the transmission fluid pressure switch for damage or debris. (Scheme 205)
15. Remove the manual detent spring retaining bolt.
16. Remove the manual detent spring. (Scheme 206)
17. Inspect the manual detent spring for cracks or damage. CAUTION: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages.
18. Remove the remaining valve body bolts.
19. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. (Scheme 207)

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

1. Install the 7 checkballs in the valve body. (Scheme 208)
2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 207)
3. Verify the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). (Scheme 209)
4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. (Scheme 210) NOTE: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified.
5. 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. (Scheme 211) Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: M6 X 1.0 X 65.0 (1). M6 X 1.0 X 54.4 (2). M6 X 1.0 X 47.5 (3). M6 X 1.0 X 35.0 (4). M8 X 1.0 X 20.0 (5). M6 X 1.0 X 12.0 (6). M6 X 1.0 X 18.0 (7).
6. Install the manual detent spring.
7. Install but DO NOT tighten the manual detent spring retaining bolt. (Scheme 206)
8. Install the transmission fluid pressure switch. (Scheme 204)
9. Install but DO NOT tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 204) NOTE: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation.
10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. (Scheme 211) Tighten the control valve body bolts (in sequence) to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
11. Ensure the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
12. Install the TCC solenoid with a new "O" ring seal to the valve body.
13. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. (Scheme 212)
15. Place the tab between the valve body and the pressure switch in the location shown (2). See. Press the harness into position on the valve body bolt bosses (1, 3). (Scheme 213)
16. Install the TCC PWM solenoid (1) to the control valve body.
17. Install the TCC PWM solenoid retainer (2). (Scheme 197)
18. Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 202) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
19. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch. (Scheme 155) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
20. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154009-S14313116262003050100000) under LUBRICATION.

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

Scheme 213

1. Raise and support the vehicle.
2. Disconnect the Vehicle Speed Sensor (VSS) electrical connector (2). (Scheme 214)
3. Remove the bolt. (Scheme 215)
4. Remove the VSS.
5. Remove the "O" ring seal.

Scheme 214

Scheme 215

1. Install the "O" ring seal onto the VSS. (Scheme 215)
2. Coat the "O" ring seal with a thin film of transmission fluid.
3. Install the VSS.
4. Install the VSS bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
5. Connect the VSS electrical connector (2). (Scheme 214)
6. Lower the vehicle.
7. Refill the fluid as required. See «LUBRICATION»(ref-154009-S42434605272003050100000).

1. Remove the exhaust pipe. See.
2. Remove the heat shield bolts. (Scheme 166)
3. Remove the heat shield.
4. Remove the oil pan bolt below the servo.
5. Install the servo cover depressor. (Scheme 216)
6. Tighten the bolt on servo cover depressor in order to compress the servo cover.
7. Remove the servo cover ring. (Scheme 217)
8. Remove the servo cover depressor.
9. Remove the servo cover and "O" ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the "O" ring seal before removing the cover. (Scheme 218)
10. Remove the 2-4 servo. (Scheme 219)
11. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: Cracks. Scoring. Burrs and nicks.

Scheme 216

Scheme 217

Scheme 218

Scheme 219

1. Install NEW seals onto the servo pistons and the servo cover.
2. Install the 2-4 servo. (Scheme 219)
3. Install the servo cover depressor.
4. Tighten the bolt on servo cover depressor in order to compress the servo cover. (Scheme 216)
5. Install the servo cover ring.
6. Remove the servo cover depressor.
7. Install the oil pan bolt. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
8. Install the heat shield and bolts. (Scheme 166) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154009-S29611689822003050100000).
9. Install the exhaust pipe.
10. Fill transmission to proper level with appropriate fluid. See «LUBRICATION»(ref-154009-S42434605272003050100000).