Automatic Transmission - Servicing - Allison: Removal & Installation Chevrolet Silverado 2500

Removal

Note. It would be helpful to record the amount of transmission fluid lost during this procedure. Fluid in good condition, drained into a clean container, may be reused.

1. Raise and support the vehicle. Remove drain plug (7) and drain plug seal (6) from oil pan (5). (Scheme 290)
2. Allow the fluid to drain into a suitable container. Inspect the drained fluid. See «CHECKING FLUID CONDITION»(ref-138386-S14807443272002041000000) under CHECKING FLUID LEVEL & CONDITION (TRANSMISSION).
3. Remove the 12 oil pan bolts (8). Hold the oil pan in position as the last bolt is removed. Remove oil pan (5) and gasket (3). Inspect magnet (4). (Scheme 290) Excessive metallic particles or large metallic particles may indicate need for overhaul or replacement of the transmission.
4. Remove suction filter (2) by pulling straight down where the suction tube is seated in the main housing. Remove suction seal (1) from the filter or from the seal bore in the main housing. Discard the old seal. Discard the filter, if it is being replaced.

Installation

1. Remove all gasket material from the main housing. Remove any scratches from the main housing that would cause a split line leak. Place a new seal (1) on the tube of suction filter (2), if it was removed. Ensure the seal locates against the shoulder on the suction filter tube.
2. Push the filter (2) and seal (1) into the seal bore in the main housing. Position the suction filter properly. (Scheme 290)
3. Install 2 headless guide studs (M8 x 1.25) into opposite corners of the oil pan mounting face on the main housing. Place a gasket (3) on the oil pan and align the bolt holes. (Scheme 290) Slide the gasket (3) and oil pan (5) over the guide bolts and hold them in place while installing 2 bolts (8) to hold the parts in place.
4. Install the remainder of the 12 oil pan bolts (2 will replace the guide studs). Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
5. Reinstall drain plug (7) and drain plug seal (6) and tighten to specification. (Scheme 290) See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000). Lower the vehicle.
6. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-138386-S41518425362002040900000) and «FLUID CAPACITIES»(ref-138386-S27145948502002040900000).

Scheme 290

REMOVAL & INSTALLATION

1. Remove the front grill assembly. Place a drain pan under the vehicle.
2. Disconnect the transmission oil cooler lines from the auxiliary cooler. See «AUXILIARY OIL COOLER HOSE/PIPES & FITTINGS»(ref-138386-S17395518392002041100000).
3. Remove the auxiliary oil cooler bolts (1) and push pins (2). Remove the auxiliary oil cooler from the vehicle. (Scheme 291)

1. Install the auxiliary oil cooler to the vehicle. Install the bolts (1) and the push pins (2) that retain the auxiliary oil cooler to the radiator brace. (Scheme 291)
2. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
3. Connect the transmission oil cooler lines to the auxiliary cooler. See «AUXILIARY OIL COOLER HOSE/PIPES & FITTINGS»(ref-138386-S17395518392002041100000).
4. Install the front grill assembly. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138386-S33641038992002040900000).

Scheme 291

1. Raise the vehicle. Pull the plastic cap back from the quick connect fitting. Remove the cooling lines from the clips. Remove the 2 retaining rings securing the 2 cooling lines to the transmission. (Scheme 291)
2. Using a bent tip screwdriver, pull on 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 the fitting. (Scheme 292) Discard the retaining ring.
3. Pull the cooling line straight out from the quick connect fitting. (Scheme 293) Repeat this procedure to remove all the remaining cooling lines from quick connect fittings.
4. For both vehicles with and without auxiliary cooling, remove the cooling lines from the radiator. (Scheme 294)
5. Remove the oil cooling lines from the auxiliary oil cooler. (Scheme 295)

1. Install a NEW retaining ring (E clip) into the quick connect fitting using the following procedure: Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 296) Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears through the 3 slots on the fitting. (Scheme 297) Do not install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 298)
2. Ensure the 3 retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. (Scheme 299) Install the NEW retaining ring (E-clip) into the remaining quick connect fittings. Install the cooler line into the quick connect fitting. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. (Scheme 300)
3. Install the cooler lines to the vehicle. (Scheme 293) DO NOT use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 301)
4. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Position (snap) the plastic cap onto the fitting. (Scheme 302) Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. Ensure the plastic cap is fully seated against the fitting.
5. Ensure no gap is present between the cap and the fitting. (Scheme 303) Ensure the Yellow identification band on the tube is hidden within the quick connect fitting. A hidden Yellow identification band indicates proper joint seating. (Scheme 304) DO NOT install the cooler line end into the fitting incorrectly. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting.
6. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall the cooler line per the installation procedure. For vehicles without auxiliary cooling, install the cooling lines to the radiator.
7. For vehicles with auxiliary cooling, install the cooling lines to the radiator and the cooling lines to the auxiliary oil cooler.
8. On all vehicles, install the cooling lines to the transmission. Install the cooling lines to the clips. Ensure all of the protective plastic caps are positioned over all of the quick connect fittings. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138386-S33641038992002040900000).

Scheme 292

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

Scheme 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

1. Use a standard strap type filter wrench to remove or install the control main filter. Remove filter (4) by rotating it in the counterclockwise direction. see scheme 2
2. Remove the magnet (2) from the filter attachment tube (1) in the converter housing or from the filter element. see scheme 2
3. Clean any metal debris from the magnet. Presence of any metal pieces larger than dust may indicate that transmission replacement or overhaul is required.
4. Remove the filter attachment tube (1) from the converter housing. see scheme 2

1. Install the filter attachment tube (1). see scheme 2
2. Tighten the attachment tube to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
3. Reinstall the magnet (2) onto the filter attachment tube (1). Lubricate the gasket (3) on the control main filter with transmission fluid. see scheme 2
4. Install, by hand, the control main filter (4) until the gasket on the control main filter touches the converter housing.
5. Turn the filter ONE FULL TURN ONLY after gasket contact. Check the transmission fluid level. See «CHECKING FLUID LEVEL & CONDITION (TRANSMISSION)»(ref-138386-S39749265502002040900000) under LUBRICATION.

1. Using the wiring harness connector remover, disconnect the external wiring harness from the main transmission connector. (Scheme 305)
2. Remove the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION. NOTE: The transmission main connector is actually one end of the internal harness that protrudes through the main housing.
3. Place a 1 3/16" (30 mm) or 12-point deep socket or box end (2) over the connector (1). Push inward on the socket or wrench to release the retainer "feet" that attach the connector (1) to the main housing. (Scheme 306) Remove the wrench. Push inward on the electrical connector to separate it from the main housing. This allows the internal wiring harness to remain with the control valve assembly as it is removed.
4. Remove the 2 detent spring bolts (3). Remove the detent spring assembly (2). (Scheme 307) NOTE: As the control valve assembly is removed, be careful not to lose the manual selector valve pin or allow the manual selector valve to slide out of the control valve assembly.
5. Remove 14 bolts at locations marked (1). (Scheme 308) Support the control valve assembly (about 10 pounds) and remove the last bolt marked (1).
6. Lower the control valve assembly (1) to clear the dowel pins (2) in the main housing. (Scheme 309)
7. Move the control valve assembly (4) sideways to disengage pin (1) in the manual selector valve (2) from the slot in detent lever (3). (Scheme 310) Remove the control valve assembly (4).

1. Move the control valve assembly (4) into position under the main housing. Engage the pin (1) in the manual selector valve (2) into the slot in the detent lever (3). (Scheme 310)
2. Align the control valve assembly (1) with the dowel pins (2) in the main housing. (Scheme 309) Seat the control valve assembly against the main housing and hold it in position. Install one bolt marked (1) to hold the control valve assembly in place.
3. Reinstall the remaining 14 bolts marked (1) that fasten the control valve assembly to the main housing. (Scheme 308) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
4. Push the main transmission connector (2) outward through the hole (1) in the main housing until the retaining "feet" on the connector are nearing the locked position. (Scheme 311) Use the internal wiring harness installer to complete the seating of the retaining "feet" that lock the connector (1) into the main housing. (Scheme 312)
5. Install the detent spring assembly (2) onto the control valve assembly.
6. Confirm the roller of the detent spring assembly rests on the detent lever (1). Install 2 detent spring bolts (3). Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
7. Install the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION. Connect the external wiring harness to the main transmission connector.

Scheme 305

Scheme 306

Scheme 307

Scheme 308

Scheme 309

Scheme 310

Scheme 311

Scheme 312

1. Remove the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION. Disconnect the internal wiring harness from the solenoid being changed.
2. Remove the 2 bolts (2) that fasten reverse signal tube (1) to the control valve assembly. Remove the reverse signal tube. (Scheme 322) NOTE: When the A/B solenoid bracket (5) is removed, there are 2 sets of accumulators (3) and springs (6) which may fall from their bores. (Scheme 313) Ensure to catch them so they are not damaged. The A/B solenoid bracket (5) MUST not be modified. Ensure the angle between the 2 bracket surfaces is 90 degrees or less. Replace the bracket if the angle is more than 90 degrees.
3. To remove "A" or "B" solenoid, remove 3 bolts (4) and the A/B solenoid bracket (5). Remove accumulators (3) and springs (6) if they do not fall out when bracket (5) is removed. Note the position of the solenoid connector and pull the solenoid (1) or (8) out of the bore in the control valve assembly. The O-ring on the solenoid provides the resistance felt during removal.
4. Remove the solenoid retainer (1) for the "C", "D", "E", or "F" solenoids. Note the position of the solenoid connector and pull the solenoid (3) out of the bore in the control valve assembly. The O-rings (2) provide the resistance felt during removal. (Scheme 314)

1. Lubricate new O-rings (2) with clean transmission fluid. Install the O-rings and push the new solenoids into the control valve body bore with the wiring harness connector in the correct position.
2. Reinstall the 2 accumulators (3) and springs (6) before installing the A/B solenoid bracket (5). The valve (3) goes in the bore first with the hollow end facing outward, followed by the spring (6) which goes inside the hollow portion of the valve. (Scheme 313)
3. Install the solenoid retainers (1) for the "C", "D", "E", and "F" solenoids. (Scheme 314)
4. Reinstall the solenoid retaining bracket (5). Install 3 bolts (4) and tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
5. Install the reverse signal tube. Install the 2 bolts (2) that fasten reverse signal tube (1) to the control valve assembly. (Scheme 322) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000). Reconnect the internal wiring harness to the solenoid. Install the oil pan and suction filter. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138386-S33641038992002040900000).

Scheme 313

Scheme 314

1. The transmission case has provisions that enable the fill tube to be installed on either the right or left side of the transmission. If servicing the plug and/or seal opposite the fill tube, go to step 4.
2. Remove the transmission fluid level indicator. Raise and suitably support the vehicle. Remove the nuts attaching the fill tube to the transmission. (Scheme 315)
3. Place a drain pan under the transmission to catch any dripping fluid. Loosen the fill tube from the transmission.
4. Remove the fill tube and seal from the vehicle. Remove the fill tube plug (1). Remove the fill tube plug seal (2). (Scheme 316)

1. Install a new fill tube plug seal (2) into the main housing. Align the tab on the fill tube plug (1) with the tang on the main housing. Install the fill tube plug (1). (Scheme 316)
2. Press the plug into the seal (2) until the tab on the fill tube plug locks into place in the notch on the main housing. Install the new fill tube seal to the transmission. (Scheme 315)
3. Install the fill tube to the transmission. Ensure the fill tube bracket is positioned properly on the studs. (Scheme 315)
4. Install the fill tube bracket nuts to the studs. (Scheme 315) Tighten the fill tube bracket nuts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000). Lower the vehicle. Fill the transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138386-S33641038992002040900000).

Scheme 315

Scheme 316

1. Raise and suitably support the vehicle. Remove the bolts (2) from the front heat shield (1). (Scheme 317)
2. Remove the front heat shield (1) from the transmission. (Scheme 317)
3. Remove the bolt (4) and the nut (5) from the side heat shield (3). Remove the side heat shield (3) from the transmission. (Scheme 317)

1. Install the side heat shield (3) to the transmission. (Scheme 317)
2. Install the bolt (4) and the nut (5) to the side heat shield (3). (Scheme 317)
3. Tighten the bolt (4) and the nut (5) to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
4. Install the front heat shield (1) to the transmission. Install the bolts (2) to the front heat shield (1). (Scheme 317) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000). Lower the vehicle.

Scheme 317

Remove the oil pan and suction filter. See INTERNAL FILTER REPLACEMENT under LUBRICATION. Remove the 2 detent spring bolts (3). Remove the detent spring assembly (2). (Scheme 307)

Install the detent spring assembly (2) onto the control valve assembly. Confirm the roller of the detent spring assembly rests on the detent lever (1). (Scheme 307) Install 2 detent spring bolts (3). Tighten the bolts to specification. See TORQUE SPECIFICATIONS. Install the oil pan and suction filter. See INTERNAL FILTER REPLACEMENT under LUBRICATION.

Disconnect the hose from the hydraulic connector assembly being replaced. Remove the hydraulic connector assembly (1) and/or (2). (Scheme 318)

Install a new hydraulic connector assembly (1) and/or (2). (Scheme 318) Tighten to specification. See TORQUE SPECIFICATIONS. Connect the hose to the hydraulic connector(s).

Scheme 318

Remove the pressure tap plug (2) and O-ring (1) that is located on the bottom of the converter housing near the control main filter. (Scheme 319) Remove the O-ring from the plug and discard it.

Install a new O-ring (1) on the pressure tap plug (2). (Scheme 319) Install the plug and O-ring into the converter housing. Tighten the plug to specification. See TORQUE SPECIFICATIONS.

Scheme 319

1. Disconnect the external wiring harness from the PNP switch. Disconnect the shift linkage/cable from the shift lever (2) on the selector shaft (4). see scheme 8
2. Use wrench (1) to prevent the shift lever (2) from rotating. Remove nut (3) from the end of the selector shaft (4). see scheme 8
3. Carefully remove the shift lever (2) from selector shaft (4). Remove the two bolts (6). Remove the PNP switch (5) by sliding it outward over the selector shaft (4).

Note. If replacing the PNP switch, use the following procedure. If reinstalling old switch, use adjustment procedure. See PARK/NEUTRAL POSITION SWITCH under ADJUSTMENTS.

1. Ensure the neutral assurance bracket (2) is in the proper position on PNP switch (1). (Scheme 320)
2. Ensure the selector shaft is in the Neutral position as follows: Place a wrench on the selector shaft flats and rotate the shaft to its furthest clockwise position. Rotate the selector shaft counter clockwise 2 detents.
3. Align the PNP switch (5) with the main housing so the neutral assurance bracket is facing outward.
4. While maintaining the correct PNP switch to selector shaft alignment, slide the new PNP switch (5) over the selector shaft (4).
5. While holding the neutral assurance bracket in engagement with the PNP switch, install the 2 bolts (6) so the PNP switch may be rotated with slight effort. (Scheme 320) Tighten the 2 bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
6. Remove and discard the neutral assurance bracket. NOTE: Do not drive the selector lever onto the selector shaft. Do not use an impact wrench in order to tighten the selector lever nut. Hold the lever with a wrench while tightening the nut. Do not drive the selector lever onto the selector shaft. Do not use an impact wrench in order to tighten the selector lever nut. Hold the lever with a wrench while tightening the nut. Failure to follow these instructions may result in transmission damage.
7. Reinstall shift lever (2). Install nut (3), by hand, on the end of selector shaft (4). see scheme 8 Use a wrench (1) to keep the shift lever from rotating. Tighten shift lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
8. Reconnect the shift selector linkage/cable to the shift lever (2). Connect the external wiring harness to the PNP switch.

Scheme 320

Remove 6 bolts (3). Remove the PTO cover (2) and gasket (1). (Scheme 321) Discard the used gasket. Ensure the PTO gasket face on the main housing is free of all foreign material, nicks and scratches. To install, place the new PTO cover gasket (1) on the cover (2). Start the top center bolt (3) first. (Scheme 321) Install the other 5 bolts and tighten all bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 321

Note. Individual pressure switches cannot be replaced. When any pressure switch needs replacement, the entire assembly must be replaced.

1. Remove the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION.
2. Remove the 2 bolts (2). Remove the reverse signal tube (1). (Scheme 322)
3. Disconnect the internal wiring harness connector from the pressure switch assembly (2). Remove 5 bolts (1). Remove the pressure switch assembly (2). (Scheme 323)

1. Place the new pressure switch manifold assembly (2) in position and install one bolt (1) in a recessed location to hold it into position.
2. Start the remaining 4 bolts (1) in recessed locations and tighten the bolts by hand. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000) .
3. Connect the internal wiring harness connector to the pressure switch assembly. Install the reverse signal tube (1). Install 2 bolts (2). Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000) .
4. Install the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION.

Scheme 322

Scheme 323

1. Place the gearshift lever to the PARK position. Raise the vehicle. Ensure the transmission manual shaft is positioned to mechanical Park. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). Locate the center connector on the transmission range selector cable. (Scheme 324)
2. Pull back the White plastic cover (1) on the center connector. see scheme 10 Pull up on the center tabs of the lock button (2). see scheme 11 Ensure the gearshift lever remains in the PARK position for the best possible access to the E-clip. (Scheme 325) Remove the E-clip by pulling radially on the center section of the E-clip.
3. Pull the range selector cable center connector ends apart. Lower the vehicle and ensure the gearshift lever is still in the PARK position. Remove the instrument panel knee bolster. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK article in AUTOMATIC TRANSMISSIONS. Pull back the carpet and insulation around the driver's area.
4. Remove the cable end (1) from the steering column ball stud. Remove the retainer (2) securing the cable to the steering column. (Scheme 326) Depress the tangs and remove the cable from the steering column bracket. Remove the bolt securing the cable support to the brace. (Scheme 327) NOTE: Avoid unnecessary twisting/bending of the range selector cable when removing the cable from the support.
5. Remove the range selector cable from the support. (Scheme 328) Remove the cable grommet from the floor panel. Raise the vehicle. Remove the 2 clips on the cable from the floor panel reinforcement.
6. Remove the cable from the clips on the transfer case, if equipped. Remove the front half (column end) of the range selector cable assembly from the vehicle.

1. Route the cable through the hole in the floor panel. Install the cable to the clips on the transfer case, if equipped. Install the 2 clips on the cable to the floor panel reinforcement. Lower the vehicle. Ensure the gearshift lever is in the PARK position. Install the cable grommet to the floor panel.
2. Install the cable to the steering column bracket. Ensure the tangs fully seat (snap) into the steering column bracket. Install the retainer (2) securing the cable to the steering column. Install the cable end (1) to the steering column ball stud. (Scheme 326)
3. Install the cable to the support. Install the bolt securing the cable support to the brace. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000). Install the carpet and insulation around the driver's area. Install the instrument panel knee bolster. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK article in AUTOMATIC TRANSMISSIONS.
4. Raise the vehicle. Ensure the transmission manual shaft lever is in the mechanical Park position. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). (Scheme 324)
5. The new front half (column end) of the cable will contain a new pre-installed E-clip. Grasp the front half (column end) of the transmission cable (1) in the left hand and the rear half (transmission end) of the transmission cable (2) in the right hand. (Scheme 329)
6. Align the outside diameter of cable (2) with the inside of the diameter of cable (1). Push the end of the cable (2) inside the end of cable (1) until the blue spring on cable is fully compressed. Pushing together the 2 ends of the cable will engage the inner wire and lock both cable wires together. NOTE: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the cable end (2) during this procedure.
7. Release the cable end (2) and allow the Blue spring to tension/adjust the cable system. see scheme 13 Pull the White cover (3) on the cable end (1) back. see scheme 14 Push the Natural colored lock button (2) down to engage the locking teeth on the cable end (1). see scheme 14
8. Release the White cover (1). see scheme 15 Verify the White cover (1) conceals the Natural colored lock (2). If the White cover (1) does not conceal the Natural colored lock (2), repeat the cable adjustment procedure.
9. Lower the vehicle and test the transmission for proper shift operation. If all of the gear positions cannot be achieved, repeat the cable adjustment procedure.

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

1. Position the gearshift lever to the PARK position. Raise the vehicle. Ensure the transmission manual shaft is positioned to mechanical Park position. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1). (Scheme 324)
2. Locate the center connector on the transmission range selector cable. Pull back the White plastic cover (1) on the center connector. see scheme 10 Pull up on the center tabs of the lock button (2). see scheme 11
3. Ensure the gearshift lever remained in the PARK position for the best possible access to the E-clip. Remove the E-clip by pulling radially on the center section of the E-clip. (Scheme 325)
4. Pull the range selector cable center connector ends apart. Remove the retainer that secures the cable to the bracket. Depress the tangs and remove the cable from the bracket. (Scheme 330)
5. Remove the cable to from the clips on the transfer case, if equipped. Remove the rear half (transmission end) of the range selector cable from the vehicle.

1. Install the rear half transmission end of the range selector cable to the vehicle. Install the cable to the clips on the transfer case, if equipped. Align and install the cable to the bracket. Install the retainer that secures the cable to the bracket.
2. Install a new E-clip to the front half (steering column end) of the cable. (Scheme 325) Ensure the transmission manual shaft lever is in the mechanical Park position. Install the range selector cable end (2) to the transmission range selector lever ball stud (1). (Scheme 324)
3. Grasp the front half (steering column end) of the transmission cable (1) in the left hand and the rear half (transmission end) of the transmission cable (2) in the right hand. Align the outside diameter of cable (2) with the inside of the diameter of cable (1). Push the end of the cable (2) inside the end of cable (1) until the Blue spring on cable (2) is fully compressed. (Scheme 329)
4. Pushing together the 2 ends of the cable will engage the inner wire and lock both cable wires together. NOTE: This step must be performed correctly to avoid a misadjusted cable. Do not grasp the cable end (2) during this procedure.
5. Release the cable end (2) and allow the Blue spring to tension/adjust the cable system. Pull the White cover (3) on the cable end (1) back. Push the Natural colored lock button (2) down to engage the locking teeth on the cable end (1). see scheme 12
6. Release the White cover (1). see scheme 14 Verify the White cover (1) conceals the Natural colored lock (2). see scheme 15 If the White cover (1) does not conceal the Natural colored lock (2), repeat the cable adjustment procedure.
7. Lower the vehicle and test the transmission for proper shift operation. If all of the gear positions cannot be achieved, repeat the cable adjustment procedure. See «SHIFT CABLE»(ref-138386-S17475298292002040900000) under ADJUSTMENTS.

Scheme 330

1. Remove the control valve assembly from the transmission. See «CONTROL VALVE BODY»(ref-138386-S15696376602002041000000). Remove the PNP switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-138386-S28493444922002041000000).
2. Do not mar the main housing surface around the spring pin when removing the spring pin. An unmarred surface is required to maintain the seal between the control valve assembly and the main housing.
3. Place a protective plate on the main housing surface around the spring pin (3). Place a drill bit inside spring pin (3) to prevent cutting or collapsing the pin when removing the pin. (Scheme 331) Remove the spring pin (3) from the main housing.
4. Slide the selector shaft (5) through the detent lever (4) and through the selector shaft seal. Rotate the detent lever to disengage the park pawl apply assembly (2). Remove the detent lever (4) and nut (1).

1. Place the new detent lever (4) in position in the main housing. Rotate the detent lever to engage the park pawl apply assembly (2). Reinstall the selector shaft (5) through the selector shaft seal and through the detent lever (4). (Scheme 331)
2. Place the nut (1) in position over the selector shaft. Push the selector shaft (5) into its final position in the main housing. Reinstall the spring pin (3) into the main housing that retains the selector shaft.
3. Install pin to 0.33-0.35" (8.5-9.0 mm) above main housing surface. Hand tighten nut (1). Tighten the nut (1) to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000).
4. Install the PNP switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-138386-S28493444922002041000000). Install the control valve assembly. See «CONTROL VALVE BODY»(ref-138386-S15696376602002041000000).

Scheme 331

Note. Tools required: Selector Shaft Seal Remover (J-43911), and Selector Shaft Seal Installer (J-43909).

1. Remove the PNP Switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-138386-S28493444922002041000000).
2. Ensure the jackscrew for the selector shaft seal remover is backed off and will not interfere with installation of the removal tool.
3. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. (Scheme 332) Rotate the removal tool so the threads on the end of the tool engage the steel shell (1) of the seal.
4. Use a wrench to ensure the removal tool is firmly attached to the seal shell. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed.

1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward.
2. Position the seal so it is starting to enter the seal bore. Obtain the selector shaft seal installer and remove the inner sleeve so the tool will slide over the selector shaft. (Scheme 333)
3. Slide the selector shaft seal installer into position so the end of the tool contacts the seal being installed.
4. Use a mallet to strike the selector shaft seal installer and drive the new seal into the seal bore until it is seated at the bottom of the bore.
5. Install the PNP Switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-138386-S28493444922002041000000).

Scheme 332

Scheme 333

Ensure the vehicle ignition is turned off. Disconnect the external wiring harness from the speed sensor. Remove the bolt (1) from the speed sensor and carefully remove the speed sensor (2). (Scheme 334)

Note. Do not rotate the sensor in its retaining bracket. Changing the sensor/bracket orientation may cause improper operation.

1. Install a new a O-ring (3) on the speed sensor (2). Lubricate the O-ring with clean transmission fluid. (Scheme 334)
2. Install the new speed sensor (2) into the speed sensor bore. (Scheme 334) Align the hole in the retaining bracket with the bolt hole in the speed sensor boss.
3. Install the speed sensor bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138386-S35372756022002040900000). Reconnect the external wiring harness to the speed sensor.

Scheme 334

1. Remove the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION. Disconnect the external wiring harness from the main transmission connector. (Scheme 305)
2. Use the wiring harness connector remover, if connector is not easily accessible. NOTE: The main transmission connector is actually one end of the internal wiring harness that protrudes through the main housing.
3. Place a 1 3/16" or (30 mm) 12-point deep socket or box end wrench (2) over the main transmission connector (1). (Scheme 306) Push inward on the socket or wrench to release the retaining "feet" that attach the connector (1) to the main housing. Remove the wrench.
4. Push inward on the electrical connector to separate it from the main housing. Disconnect the internal wiring harness connectors (1) from solenoids "A" through "F" and from the pressure switch assembly. (Scheme 335) NOTE: The solenoid retainers for "E" and "D" solenoids also retain tabs on the wiring harness "U" channel.
5. The solenoids will remain in position even after the solenoid retainers are removed. Remove the solenoid retainers (2) for solenoids "E" and "D". Remove the internal wiring harness from the transmission. (Scheme 336)

1. Align the tabs (8) on the new wiring harness "U" channel with the solenoid retainer slots for solenoids "E" (3) and "D" (2) on the control valve assembly. Install the solenoid retainers (14) for the "E" (3) and "D" (4) solenoids. (Scheme 336)
2. Attach the internal wiring harness connectors to their respective solenoids "A" through "F" and to the pressure switch assembly as follows: Connector No. 13 - Solenoid No. 6 Connector No. 12 - Solenoid No. 4 Connector No. 7 - Solenoid No. 5 Connector No. 10 - Solenoid No. 2 Connector No. 11 - Solenoid No. 3 Connector No. 9 - Solenoid No. 1 (Scheme 336)
3. Push the main transmission connector (2) outward through hole (1) in the main housing until the retaining "feet" on the connector are near the locked position. (Scheme 311).
4. Use the internal wiring harness installer to seat the retaining "feet" on transmission connector (1). (Scheme 312)
5. Install the oil pan and suction filter. See «INTERNAL FILTER REPLACEMENT»(ref-138386-S26214141642002041000000) under LUBRICATION. Connect the external wiring harness to the main transmission connector.

Scheme 335

Scheme 336