Automatic Transmission - 4L80-E - Service & Replacement: Removal & Installation Chevrolet Silverado 1500 HD

Park/Neutral Position Switch Replacement

Tools Required

J 41364-A Park Neutral Switch Aligner

Scheme 1086

Scheme 1087

Scheme 1088

1. Apply the park brake.
2. Shift the transmission into neutral.
3. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-188974-S33950512222005091300000) .
4. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
5. Disconnect the park/neutral position (PNP) switch electrical connectors (5).
6. Remove the range selector cable end (2) from the range selector lever ball stud (1).
7. Remove the control lever to the manual shaft nut.
8. Remove the control lever from the manual shaft.
9. Remove the PNP switch bolts.
10. Remove the PNP switch from the manual shaft. If the PNP switch does not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs.

Scheme 1089

Scheme 1090

Scheme 1091

Scheme 1092

Scheme 1093

1. Install the PNP switch to the manual shaft by aligning the switch hub flats with the manual shaft flats.
2. Slide the PNP switch onto the manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. IMPORTANT: 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. Position the J 41364-A onto the PNP 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. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
5. Rotate J 41364-A until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten Tighten the bolts to 25 N.m (18 lb ft).
6. Remove J 41364-A from the PNP switch. If installing a new switch, remove the positive assurance bracket at this time.
7. Install the control lever to the manual shaft with the nut.
8. Install the manual shaft nut. Tighten Tighten the nut to 25 N.m (18 lb ft).
9. Install the range selector cable end (2) to the range selector lever ball stud (1).
10. Connect the PNP switch electrical connectors (5).
11. If equipped with 4WD, install the front propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - FRONT»(ref-188974-S33950512222005091300000) .
12. Lower the vehicle.
13. Check the PNP 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.

Removal Procedure

Scheme 1094

Scheme 1095

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
2. Disconnect the output speed sensor (2) electrical connector.
3. Remove the output speed sensor bolt.
4. Remove the output speed sensor (2).
5. Inspect the output speed sensor (2) for any evidence of damage.

Scheme 1096

Scheme 1097

1. Lubricate the output speed sensor seal with automatic transmission fluid.
2. Install the output speed sensor (2). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the output speed sensor bolt. Tighten Tighten the bolt to 11 N.m (96 lb in).
4. Connect the output speed sensor (2) electrical connector.
5. Lower the vehicle.

Scheme 1098

Scheme 1099

1. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .
2. Remove the park/neutral position (PNP) switch. Refer to «Park/Neutral Position Switch Replacement»(ref-188999-S09395435472005091400000) .
3. Remove the manual shaft nut and pin.
4. Remove the detent lever and actuator.
5. Remove the parking pawl bracket bolts.
6. Remove the parking pawl return spring.
7. Use the modified screw extractor in order to remove the plug.
8. Remove the parking pawl shaft retainer, shaft and pawl. IMPORTANT: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever.
9. Remove the manual shaft.
10. Remove the manual shaft seal.

Scheme 1100

Scheme 1101

1. Install the pawl shaft.
2. Install the parking pawl.
3. Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent.
4. Install the retainer.
5. Install the pawl return spring.
6. Install the detent lever to the actuator.
7. Install the actuator over the parking pawl.
8. Install the manual shaft seal.
9. Lubricate the manual shaft with transmission oil and install the manual shaft into the case.
10. Install the nut on the shaft.
11. Install the roll pin. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
12. Install the parking lock bracket bolts. Tighten Tighten the bolts to 24 N.m (18 lb ft).
13. Install the PNP switch. Refer to «Park/Neutral Position Switch Replacement»(ref-188999-S09395435472005091400000) .
14. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .
15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-188999-S00354647062005091400000) .

Pressure Regulator Replacement

Tools Required

J 36850 Transjel®

Scheme 1102

Scheme 1103

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
2. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) . CAUTION: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result.
3. Remove the reverse boost valve bushing retainer ring (2).
4. Remove the following from the reverse boost valve cylinder: The reverse boost valve bushing The reverse boost valve The pressure regulator spring retainer The pressure regulator spring The pressure regulator valve The reverse boost valve bushing

Scheme 1104

Scheme 1105

1. Install the pressure regulator valve using J 36850.
2. Pre-assemble the following parts: The reverse boost valve bushing A new reverse boost valve A new pressure regulator spring retainer The added isolator pressure regulator spring The 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.
5. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .
6. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-188999-S00354647062005091400000) .

Scheme 1106

Scheme 1107

1. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) . CAUTION: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result.
2. Remove the valve bore plug retainer ring (1).
3. Remove the following parts: The valve bore plug The TCC valve The TCC valve spring

Scheme 1108

Scheme 1109

1. Install the following parts: The TCC valve spring The TCC valve The valve bore plug
2. Install the valve bore plug retainer ring (1).
3. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .

Accumulator Housing Replacement

Tools Required

J 25025-5 Valve Body Align Pin

1. Remove the valve body. Refer to «Valve Body And Pressure Switch Replacement»(ref-188999-S08998294522005091400000) .
2. Remove the 3rd and 4th clutch accumulator housing bolts (1).
3. Remove the 3rd and 4th clutch accumulator housing (8).
4. Remove the accumulator housing gasket (6). The accumulator housing gasket may be stuck to the spacer plate (5).
5. Remove the 3rd clutch accumulator piston spring (7).
6. Remove the 4th clutch accumulator piston spring (2).
7. Remove the valve body spacer plate (5).
8. Remove the valve body to spacer plate gasket (4) from the spacer plate (5).

Scheme 1110

Scheme 1111

1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in).
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.
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.

Installation Procedure

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

Scheme 1116

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

1. Install a new retaining ring into the quick connect fitting using the following procedure
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
6. Install the cooler line into the quick connect fitting.
7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting.
9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. IMPORTANT: Do not manually depress the retaining clip when installing the plastic cap.
10. 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.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating.
15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «TRANSMISSION FLUID CHECKING PROCEDURE»(ref-188998-S01197457772005091400000) .

Scheme 1122

1. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .
2. Remove the forward servo cover bolts, cover, and gasket.
3. Remove the following parts: 3.1. Forward servo piston pin (5) 3.2. O-ring seal (4) 3.3. Servo piston (3) 3.4. Retainer (2) 3.5. Piston spring (1)

Scheme 1123

1. Install the following parts: Piston spring (1) Retainer (2) Servo piston (3) O-ring seal (4) Forward servo piston pin (5) NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the forward servo gasket, cover, and bolts. Tighten Tighten the bolts to 24 N.m (18 lb ft).
3. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .

Scheme 1124

Scheme 1125

Scheme 1126

1. Remove the grille assembly. Refer to «GRILLE REPLACEMENT (OLD STYLE)»(ref-189020-S07215943912005091100000) or «GRILLE REPLACEMENT (NEW STYLE GMC)»(ref-189020-S24749606852005091100000) or «GRILLE REPLACEMENT (NEW STYLE CHEVROLET)»(ref-189020-S39599610392005091100000) .
2. Remove the transmission fluid cooler hose from the Auxiliary oil cooler. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
3. Remove the transmission fluid cooler hose from the radiator. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
4. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
5. Remove the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
6. Remove the transmission fluid cooler hoses from the transmission. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
7. Remove the transmission fluid cooler hoses from the retainer on the engine.
8. Remove the transmission fluid cooler hoses from the vehicle.

Scheme 1127

Scheme 1128

Scheme 1129

1. Install the transmission fluid cooler hoses to the vehicle.
2. Install the transmission fluid cooler hoses to the transmission. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
3. Install the transmission fluid cooler hoses to the retainer on the engine.
4. Install the engine protection shield. Refer to Engine Protection Shield Replacement in Frame and Underbody.
5. Lower the vehicle.
6. Install the transmission fluid cooler hose to the radiator. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
7. Install the transmission fluid cooler hose from the Auxiliary oil cooler. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
8. Install the grille assembly. Refer to «GRILLE REPLACEMENT (OLD STYLE)»(ref-189020-S07215943912005091100000) or «GRILLE REPLACEMENT (NEW STYLE GMC)»(ref-189020-S24749606852005091100000) or «GRILLE REPLACEMENT (NEW STYLE CHEVROLET)»(ref-189020-S39599610392005091100000) .

Scheme 1130

1. Remove the grille assembly. Refer to «GRILLE REPLACEMENT (OLD STYLE)»(ref-189020-S07215943912005091100000) or «GRILLE REPLACEMENT (NEW STYLE GMC)»(ref-189020-S24749606852005091100000) or «GRILLE REPLACEMENT (NEW STYLE CHEVROLET)»(ref-189020-S39599610392005091100000) .
2. Remove the transmission fluid cooler hoses from the auxiliary cooler. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000)
3. Remove the auxiliary oil cooler bolts (1).
4. Remove the auxiliary oil cooler push pins (2).
5. Remove the auxiliary oil cooler from the vehicle.

Scheme 1131

1. Install the auxiliary oil cooler to the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the bolts (1) to the radiator brace. Tighten Tighten the bolts to 12 N.m (106 lb in).
3. Install the push pins (2) to the radiator brace.
4. Connect the transmission oil cooler lines to the auxiliary cooler. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000) .
5. Install the grille assembly. Refer to «GRILLE REPLACEMENT (OLD STYLE)»(ref-189020-S07215943912005091100000) or «GRILLE REPLACEMENT (NEW STYLE GMC)»(ref-189020-S24749606852005091100000) or «GRILLE REPLACEMENT (NEW STYLE CHEVROLET)»(ref-189020-S39599610392005091100000) .

Scheme 1132

1. Remove the vent hose clip.
2. Remove the vent hose from the transmission vent.

Scheme 1133

1. Install the vent hose to the transmission.
2. Install the vent hose to the clip. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the bolt and the clamp. Tighten Tighten the bolt to 10 N.m (89 lb in).

Manual Shift Shaft Seal Replacement

Tools Required

1. J 43911 Selector Shaft Seal Remover
2. J 43909 Selector Shaft Seal Installer

Scheme 1134

1. Remove the park/neutral position (PNP) switch. Refer to «PARK/NEUTRAL POSITION SWITCH REPLACEMENT»(ref-188998-S32315096382005091400000) .
2. Ensure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal.
3. Rotate the J 43911 so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell.
4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed.

Scheme 1135

1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore.
2. Using J 43909, remove the inner sleeve so that the tool will slide over the selector shaft.
3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore.
4. Install the PNP switch. Refer to «PARK/NEUTRAL POSITION SWITCH REPLACEMENT»(ref-188998-S32315096382005091400000) .
5. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «TRANSMISSION FLUID CHECKING PROCEDURE»(ref-188998-S01197457772005091400000) .

Valve Body and Pressure Switch Replacement

Tools Required

1. J 25025-5 Valve Body Align Pin
2. J 36850 Transjel®

Scheme 1136

Scheme 1137

Scheme 1138

Scheme 1139

Scheme 1140

Scheme 1141

Scheme 1142

1. Ensure that removal of the valve body is necessary before proceeding. IMPORTANT: The following components can be serviced without removing the valve body: 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.
3. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .
4. Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. IMPORTANT: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body.
5. Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2).
6. Remove the TFP manual valve position switch.
7. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components.
8. Remove the lube oil pipe bolt (6) and retainer (7).
9. Remove the lube oil pipe (5).
10. Remove the manual shaft detent spring bolt and spring (3). IMPORTANT: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages.
11. Remove the remaining valve body bolts.
12. Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve.
13. Remove the valve body (2) which includes the following: The accumulator housing (1) The valve body to the spacer plate gasket The spacer plate
14. Remove the manual valve (1) from the valve body.
15. Inspect the manual valve for nicks and burrs.
16. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate.
17. Remove the PWM screen (1) from the case passage.
18. Remove the manual 2-1 band servo (1).
19. Remove the servo piston cushion spring (2).
20. Remove the manual 2-1 band servo piston pin retainer ring (4).
21. Remove the manual 2-1 band servo piston pin (1).
22. Remove the manual 2-1 band servo piston seal (2). IMPORTANT: 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.
23. Remove the eight checkballs (nine checkballs for some models).

Scheme 1143

Scheme 1144

Scheme 1145

Scheme 1146

Scheme 1147

Scheme 1148

Scheme 1149

Scheme 1150

1. Install the 8 checkballs (9 checkballs for some models) into the 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 J 36850.
2. Install the PWM screen into the valve body.
3. Install the new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3).
4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3).
5. Install the manual 2-1 band servo piston pin retainer ring (4).
6. Install the manual 2-1 band servo piston cushion spring (2). IMPORTANT: 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 (1).
8. Install the manual valve (1) into the valve body.
9. To aid in alignment and assembly, install J 25025-5.
10. Install the valve body gasket (6).
11. Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body.
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. Tighten Tighten the bolts to 11 N.m (97 lb in).
15. Remove J 25025-5.
16. Install the manual shaft detent roller and spring (3) and bolts.
17. Install the 2 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 valve body.
20. Install the lube oil pipe retainer (7) and the bolt (6). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
21. Install the valve body bolts and tighten in the order shown. Tighten Tighten the bolts to 11 N.m (97 lb in).
22. Install the remaining valve body bolts. Tighten Tighten the bolts to 11 N.m (97 lb in).
23. Connect the internal wiring harness to the valve body electrical components.
24. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .

Transmission Extension Housing Rear Oil Seal Replacement

Tools Required

1. J 41505 Output Shaft Seal Installer
2. J 6125-1B Slide Hammer
3. J 23129 Universal Seal Remover
4. J 36850 Transmission Assembly Lubricant

Scheme 1151

1. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
2. Place a drain pan under the vehicle.
3. Remove the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-188974-S21653132742005101300000) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-188974-S07137564912005101300000) .
4. Using the J 6125-1B (1) and the J 23129 (2), remove the output shaft seal (3) from the extension housing (4).
5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to «Transmission Extension Housing Assembly Replacement»(ref-188999-S19368542962005091400000) .

Scheme 1152

1. Lubricate the inside diameter of the new seal with J 36850.
2. Use the J 41505 (1) with a soft faced mallet to install the seal (2).
3. Install the seal (2) to the extension housing (3).
4. Install the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-188974-S21653132742005101300000) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-188974-S07137564912005101300000) .
5. Remove the drain pan and lower the vehicle.
6. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-188999-S00354647062005091400000) .

Scheme 1153

1. Raise and suitably support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
2. Support the transmission with a transmission jack.
3. Place a drain pan under the vehicle.
4. Remove the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-188974-S21653132742005101300000) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-188974-S07137564912005101300000) .
5. Remove the transmission support and the transmission mount. Refer to «Transmission Mount Replacement»(ref-188999-S40419565912005091400000) .
6. Remove the case extension bolts (3).
7. Remove the case extension (1).
8. Remove and discard the case extension O ring seal (2).

Scheme 1154

1. Install a new case extension O ring seal (2).
2. Install the case extension (1). NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
3. Install the case extension bolts (3). Tighten Tighten the bolts (3) to 34 N.m (25 lb ft).
4. Install the transmission support and the transmission mount. Refer to «Transmission Mount Replacement»(ref-188999-S40419565912005091400000) .
5. Install the propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-188974-S21653132742005101300000) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-188974-S07137564912005101300000) .
6. Remove the drain pan and the transmission jack.
7. Lower the vehicle.
8. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-188999-S00354647062005091400000) .

Scheme 1155

Scheme 1156

1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
2. Support the transmission with a transmission jack.
3. Remove the transmission mount to the transmission support retaining nut or nuts.
4. Raise the transmission to take the weight off of the mount.
5. Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1).
6. Raise the transmission just enough to remove the transmission mount.
7. Remove the transmission mount from the vehicle.

Scheme 1157

Scheme 1158

1. Install the transmission mount to the vehicle. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
2. Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). Tighten Tighten the bolts to 50 N.m (37 lb ft).
3. Lower the transmission.
4. Install the transmission mount to the transmission support retaining nut or nuts. Tighten Tighten the nut or nuts to 40 N.m (30 lb ft).
5. Remove the transmission jack.
6. Lower the vehicle.

Transmission Replacement

Tools Required

J 21366 Converter Holding Strap

Scheme 1159

Scheme 1160

Scheme 1161

Scheme 1162

Scheme 1163

1. Raise the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-188958-S04533146952005091100000) .
2. Drain the transmission fluid. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-188999-S02614882662005091400000) .
3. Remove the rear propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-188974-S21653132742005101300000) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-188974-S07137564912005101300000) .
4. Support the transmission with a suitable jack.
5. Remove the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
6. Remove the exhaust manifold pipe.
7. Remove the transmission mount. Refer to «Transmission Mount Replacement»(ref-188999-S40419565912005091400000) .
8. Remove the transfer case, if equipped. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-188978-S31375886912005091300000) for NVG 149-NP or «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-188979-S03703728522005091300000) for NVG 236/246-NP8.
9. Remove the range selecter cable from the transmission range selecter lever ball stud and bracket. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-188999-S22798991402005091400000) .
10. Disconnect the electrical harness from the park/neutral position switch, the input speed sensor, and the output speed sensor.
11. Disconnect the wire harness from the wire loom on the left side of the transmission.
12. Cut the tie strap to separate the vent hose from the wiring harness.
13. Remove the flywheel inspection cover.
14. Mark the torque converter to flywheel orientation.
15. Remove the torque converter bolts.
16. Remove the transmission heat shield.
17. Disconnect the transmission oil cooler lines from the transmission. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000) .
18. Plug the transmission oil cooler line connectors in the transmission case.
19. Remove the stud and the bolt on the right side securing the transmission to the engine.
20. Remove the remaining six studs and the one bolt securing the transmission to the engine.
21. Install the J 21366 onto the transmission bell housing to retain the torque converter.
22. Pull the transmission straight back.
23. Remove the transmission from the vehicle.

Scheme 1164

Scheme 1165

1. Install the J 21366 onto the transmission bell housing to retain the torque converter.
2. Raise the transmission into place and remove the J 21366 from the transmission.
3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand. NOTE: Refer to «FASTENER NOTICE»(ref-175132-S17785009232005041500000) .
4. Install studs and bolt securing the transmission to the engine. Tighten Tighten the studs and the bolt to 50 N.m (37 lb ft).
5. Install the stud and bolt on the right side securing the transmission to the engine. Tighten Tighten the stud and the bolt to 50 N.m (37 lb ft).
6. Line up the marks made during removal and install the flywheel to torque converter bolts. Tighten Tighten the bolts to 60 N.m (44 lb ft).
7. Install the torque converter cover to the transmission.
8. Install the bolts securing the torque converter cover. Tighten Tighten the bolts to 33 N.m (24 lb ft).
9. Install the vent hose to the wiring harness using a new tie strap.
10. Connect the wiring harness to the wiring loom on the left side of the transmission.
11. Connect the electrical harness to the park/neutral position switch, the input speed sensor, and the output speed sensor.
12. Install the range selecter cable to the transmission range selecter lever ball stud and bracket. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-188999-S22798991402005091400000) .
13. Install the transfer case, if equipped. Refer to «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-188978-S31375886912005091300000) for NVG 149-NP or «TRANSFER CASE ASSEMBLY REPLACEMENT»(ref-188979-S03703728522005091300000) for NVG 236/246-NP8.
14. Install the transmission mount. Refer to «Transmission Mount Replacement»(ref-188999-S40419565912005091400000) .
15. Install the exhaust manifold pipe.
16. Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
17. Remove the transmission jack.
18. Install the rear propeller shaft. Refer to «PROPELLER SHAFT REPLACEMENT - ONE PIECE»(ref-188974-S21653132742005101300000) or «PROPELLER SHAFT REPLACEMENT - TWO PIECE»(ref-188974-S07137564912005101300000) .
19. Flush the transmission oil cooler and lines at this time. Refer to «Automatic Transmission Oil Cooler Flushing And Flow Test»(ref-188999-S25830964252005091400000) .
20. Connect the transmission oil cooler lines to the transmission. Refer to «Transmission Oil Cooler Line Quick Connect Fitting»(ref-188999-S13849205742005091400000) .
21. Install the transmission heat shield.
22. Install the bolts securing the heat shield to the transmission. Tighten Tighten the bolts to 17 N.m (13 lb ft).
23. Lower the vehicle.
24. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-188999-S00354647062005091400000) .