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

REMOVAL & INSTALLATION

Removal

Note. Tools required: Pump and Valve Body Alignment Pin Set (J-25025-B), and Transmission Assembly Lubricant (J-36850).

1. Remove the control valve body. See «VALVE BODY & PRESSURE SWITCH (4L60-E)»(ref-138559-S17058997092002041700000).
2. Remove the accumulator cover bolts. (Scheme 351)
3. Remove the 1-2 accumulator cover and pin, piston and springs. Remove the 1-2 accumulator piston spring. Remove the 1-2 accumulator piston and the oil seal ring. (Scheme 352)
4. Remove the oil pass cover bolt. Remove the oil pass cover. (Scheme 353)
5. Remove the spacer plate. Remove the spacer plate gaskets. (Scheme 354)
6. Remove the 3-4 accumulator spring. Remove the piston oil seal ring. Remove the 3-4 accumulator piston and the pin. (Scheme 355) Inspect the accumulator assembly.

Installation

1. Install the 3-4 accumulator pin into the transmission case. Install the 3-4 accumulator piston onto the pin. The piston legs must face the valve body. Install the 3-4 accumulator piston oil seal ring. Install the 3-4 accumulator piston spring. (Scheme 355) Install the pump and valve body alignment pin set to the transmission case.
2. Install the case gasket and the valve body gasket to the spacer plate. The case gasket is identified by a "C". The valve body gasket is identified by a "V". Use assembly lubricant to retain the gaskets to the spacer plate. Install the spacer plate and the gaskets to the transmission case. (Scheme 354)
3. Install the oil pass cover and the oil pass cover bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
4. Install the 1-2 accumulator piston with the piston legs facing toward the case. (Scheme 352) Install the oil seal ring to the accumulator cover.
5. Install the 1-2 accumulator spring onto the piston. Install the 1-2 accumulator cover and the cover bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
6. Remove the pump and valve body alignment pin set from the transmission case. Install the control valve body. See «VALVE BODY & PRESSURE SWITCH (4L60-E)»(ref-138559-S17058997092002041700000).

Scheme 351

Scheme 352

Scheme 353

Scheme 354

Scheme 355

1. Raise and support the vehicle. Remove the oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION. Remove the Transmission Fluid Pressure (TFP) manual valve position switch bolts and the TFP valve position switch. The 5 O-rings should remain attached to the TFP valve position switch.
2. Remove the control valve body assembly bolts. Remove the fluid transmission fluid level indicator stop bracket. Remove the lube oil pipe retainer and the clamp. Remove the lube oil pipe.
3. Remove the manual shaft detent spring assembly. Remove the control valve body assembly (44) which includes the accumulator assembly. (Scheme 356)
4. Remove the 3rd and 4th clutch accumulator housing bolts (53). Remove the 3rd and 4th clutch accumulator housing (51). Remove the accumulator housing gasket (47). (Scheme 356)
5. The accumulator housing gasket may be stuck to the spacer plate (46). Remove the 3rd clutch accumulator piston spring (50). Remove the 4th clutch accumulator piston spring (49). (Scheme 356)
6. Remove the control valve body spacer plate (46). Remove the control valve body assembly to spacer plate gasket (45) from the spacer plate (46). (Scheme 357)
7. Inspect all components for wear or damage. (Scheme 358) Replace all worn or damaged parts.

1. Reassemble accumulator assembly as shown. (Scheme 358)
2. Install the Guide Pin into the control valve body bolt hole where the manual shaft detent roller and spring assembly is mounted. Install the control valve body gasket (45). Install the control valve body spacer plate (46). (Scheme 357)
3. Install the 3rd and 4th clutch accumulator housing gasket (47). Install the 3rd clutch accumulator piston spring (50). This spring is the longer of the 2 springs. Install the 4th clutch accumulator piston spring (49). (Scheme 357)
4. Install the 3rd and 4th clutch accumulator housing assembly (51) onto the control valve body assembly (44). Install the 6 accumulator housing bolts (53). Start the bolts finger tight and work toward the opposite end.
5. Tighten the accumulator housing bolts sequentially. (Scheme 359) Tighten the accumulator housing bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000). Remove the guide pin.
6. Install the control valve body gasket. Install the control valve body assembly. See «VALVE BODY & PRESSURE SWITCH (4L60-E)»(ref-138559-S17058997092002041700000). Attach the manual valve to the detent lever while installing the control valve body assembly.
7. Install the transmission fluid pressure manual valve position switch. Install the transmission fluid pressure manual valve position switch bolts finger tight, then torque the bolts sequentially to specification. (Scheme 361)and «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
8. Install the manual shaft detent roller and spring assembly (3) and bolts (2 and 4). Install the 2 wiring harness clips (1) and bolts (2). Install the wiring harness clip (1) and bolts (2). (Scheme 360)
9. Install the lube oil pipe (5) with the short end into the control valve body. Install the lube oil pipe retainer (7) and the bolt (6). Install the remaining control valve body bolts. (Scheme 360) Tighten the bolts sequentially to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000). Install oil pan. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000).

Scheme 356

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Remove the grille assembly. Remove the nuts securing the 2 cooler lines to the oil cooler. Remove the 4 bolts securing the auxiliary oil cooler to the radiator support. Remove the auxiliary oil cooler. (Scheme 362)

Install the 4 bolts securing the oil cooler to the radiator support and tighten the bolts to specification. See TORQUE SPECIFICATIONS. Install the nuts securing the 2 oil cooler lines to the auxiliary oil cooler. (Scheme 362) Tighten to specification. See TORQUE SPECIFICATIONS. Reinstall the grille assembly.

Scheme 362

1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
2. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY (4L60-E)»(ref-138559-S15601074902002041700000).
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. (Scheme 363) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. 3-2 shift control solenoid. TCC PWM solenoid.
4. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 364)
5. Remove the 1-2 and 2-3 shift control solenoid retainers. Remove the 1-2 and 2-3 shift control solenoids. (Scheme 365)
6. Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 365)

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 365)
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 365)
3. Install the pressure control solenoid retainer and retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
4. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. (Scheme 363) 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 (4L60-E)»(ref-138559-S15601074902002041700000).
6. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
7. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 363

Scheme 364

Scheme 365

1. Raise and suitably support the vehicle. Support the transmission with a transmission jack. Place a drain pan under the vehicle.
2. Remove the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Remove the transmission mount.
3. Remove the case extension bolts. Remove the case extension. (Scheme 366) Remove and discard the case extension O-ring seal.

1. Install a new case extension O- ring seal. Install the case extension.
2. Install the case extension bolts. (Scheme 366) Tighten the case extension bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000). Install the transmission mount.
3. Install the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Remove the drain pan and the transmission jack. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 366

1. Raise and suitably support the vehicle. Support the transmission with a transmission jack. Place a drain pan under the vehicle.
2. Remove the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Remove the transmission support and the transmission mount.
3. Remove the case extension bolts. Remove the case extension. (Scheme 367) Remove and discard the case extension O-ring seal.

1. Install a new case extension O-ring seal. Install the case extension. (Scheme 367)
2. Install the case extension bolts. Tighten the case extension bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000). Install the transmission support and the transmission mount.
3. Install the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Remove the drain pan and the transmission jack. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 367

Raise and support the vehicle. Remove the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Remove the rear extension oil seal. (Scheme 368)

Install the new seal using rear extension seal installer and a soft faced mallet. (Scheme 369) Install the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See LUBRICATION.

Scheme 368

Scheme 369

Note. Tools required: Output Shaft Seal Installer (J-41505), Slide Hammer (J-6125-1B), Universal Seal Remover (J-23129) and Transmission Assembly Lubricant (J-36850).

Raise the vehicle. Place a drain pan under the vehicle. Remove the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Using the slide hammer and the universal seal remover, remove the output shaft seal from the extension housing. (Scheme 370) Inspect the case extension housing for damage. Replace the extension housing if necessary. See EXTENSION HOUSING ASSEMBLY (4L80-E).

Lubricate the inside diameter of the new seal with assembly lubricant. Use the output shaft seal installer with a soft faced mallet to install the seal. (Scheme 371) Install the seal to the extension housing. Install the propeller shaft. See REMOVAL & INSTALLATION in appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVE AXLES. Remove the drain pan and lower the vehicle. Fill transmission with appropriate fluid to proper level. See LUBRICATION.

Scheme 370

Scheme 371

1. Remove the transmission fluid level indicator from the fluid fill tube. Remove the bolt securing the transmission fluid fill tube bracket to the transmission housing. Remove the bolt securing the transmission fluid fill tube bracket to the transmission.
2. Raise and support the vehicle. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. (Scheme 372) Remove the transmission fluid fill tube from the transmission.
3. Pull the tube upward from the transmission. Remove the transmission fill tube seal. Clean the metal parts using solvent. DO NOT allow the solvent to enter the transmission. Dry the parts using compressed air.

1. Install a new filler tube seal into the transmission case. Install the filler tube into the seal. (Scheme 372)
2. Install the bolt securing the filler tube bracket to the transmission and tighten to Specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
3. Install the bolt securing the filler tube bracket to the engine and tighten to specification See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
4. Lower the vehicle. Install the transmission fluid level indicator. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 372

1. Remove the transmission fluid level indicator from the transmission fluid level indicator tube. If equipped with gasoline engine, remove the stud securing the transmission fluid fill tube bracket to the transmission. If equipped with diesel engine, remove the transmission fluid fill tube bracket and ground wire to the transmission.
2. On all models, raise and support the vehicle. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. Place a drain pan under the transmission.
3. Remove the transmission fluid fill tube from the transmission. (Scheme 373) Pull the tube upward from the transmission. Remove the transmission fill tube seal. (Scheme 374)

1. Install a new transmission fluid level indicator tube seal into the transmission case. (Scheme 374) Install the transmission fluid level indicator tube into the seal. (Scheme 373)
2. If equipped with gasoline engine, install the stud securing the transmission fluid level indicator tube bracket to the transmission and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
3. If equipped with diesel engine, install the bolt and nut that secures the transmission fluid level indicator tube bracket and ground wire to the transmission. Tighten the bolt and the nut to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
4. On all models, lower the vehicle. Install the transmission fluid level indicator. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 373

Scheme 374

1. Raise and support the vehicle. Remove the oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
2. Remove the 6 forward servo cover bolts, cover and gasket.
3. Remove the following parts: Forward servo piston pin (5). O-ring seal (4). Servo piston (3). Retainer (2). Piston spring (1). (Scheme 375)

1. Install the following parts: Piston spring (1). Retainer (2). Servo piston (3). O-ring seal (4). Forward servo piston pin (5). (Scheme 375)
2. Install the 6 forward servo gasket, cover, the 6 bolts and tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
3. Install the oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 375

Raise the vehicle. Remove the 2 bolts securing the transmission heat shield to the cross member. Remove the transmission heat shield from the cross member. (Scheme 376)

Install the transmission heat shield to the cross member. Install the 2 bolts securing the transmission heat shield to the cross member. Tighten the bolts to specification. (Scheme 376) Lower the vehicle.

Scheme 376

1. Raise and support the vehicle. Pull the plastic cap back from the quick connect fitting.
2. Remove the cooling lines from the clips. Remove the 2 retaining rings securing the 2 cooling lines to the transmission. Use 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 377) Discard the retaining ring.
3. Pull the cooling line straight out from the quick connect fitting. (Scheme 378) Repeat this procedure to remove all the remaining cooling lines from quick connect fittings.
4. For vehicles with and without auxiliary cooling, remove the cooling lines from the radiator. (Scheme 379)
5. Remove the oil cooling lines from the auxiliary oil cooler. (Scheme 380)

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 381) 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 382) Do not install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 383)
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 384) 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 385)
3. Install the cooler lines to the vehicle. (Scheme 378) Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 386)
4. Pull back sharply on the cooler line in order to ensure the cooler line is fastened into the quick connect fitting. Position (snap) the plastic cap onto the fitting. (Scheme 389) 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 that no gap is present between the cap and the fitting. (Scheme 387) 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 388) 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. 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 clip and the oil cooler.
8. 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. Check and add fluid as necessary. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 377

Scheme 378

Scheme 379

Scheme 380

Scheme 381

Scheme 382

Scheme 383

Scheme 384

Scheme 385

Scheme 386

Scheme 387

Scheme 388

Scheme 389

1. Raise and support the vehicle. Remove the oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
2. Remove the PNP switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-138559-S31260039142002041700000). Remove the manual shaft nut and the pin. (Scheme 390)
3. Remove the detent lever and the actuator assembly. Remove the bolts and the parking pawl bracket. Remove the parking pawl return spring. (Scheme 390)
4. Use a modified screw extractor in order to remove the plug. Remove the parking pawl shaft retainer, the shaft and the pawl. (Scheme 390) NOTE: If the manual shaft binds in the case during removal, file or sand the shaft in the area adjacent to the detent lever.
5. Remove the manual shaft. Remove the manual shaft seal.

1. Install the pawl shaft. Install the parking pawl. Install the plug using a 5/16" or (8 mm) rod with Loctite® or the equivalent. (Scheme 390)
2. Install the retainer. Install the pawl return spring. Install the detent lever to the actuator assembly. Install actuator assembly over the parking pawl.
3. Install the manual shaft seal. Lubricate the manual shaft with transmission oil and install the manual shaft into the case. Install the nut on the shaft. Install the roll pin.
4. Install the parking lock bracket with the 2 bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000). Install the PNP switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-138559-S31260039142002041700000).
5. Install the oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 390

1. Apply the parking brake. Place the transmission into Neutral. Disconnect the negative battery cable. Raise and support the vehicle.
2. Remove the nut securing the transmission control lever to the manual shaft. Remove the transmission control lever from the manual shaft. (Scheme 391)
3. Disconnect the wiring harness connector from the PNP switch.
4. Remove 2 bolts securing the PNP switch to the transmission. 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.

1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission.
2. Install the switch to the transmission with 2 bolts finger tight. Position the adjustment tool onto the park/neutral position switch. Ensure the 2 slots on the switch where the manual shaft is inserted are lined up with the lower 2 tabs on the tool.
3. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten the bolts securing the switch to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000) .
4. Remove the adjustment tool from the switch. If installing a new switch, remove the positive assurance bracket at this time. Connect the electrical connectors to the switch.
5. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000) .
6. Lower the vehicle. Check the switch for proper operation. The engine must start in the Park and Neutral positions only. If proper operation of the switch can not be obtained, replace the switch.

Scheme 391

Scheme 392

1. Raise and support the vehicle. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) 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 393)
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 394)
5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). Remove the pressure regulator valve (1). (Scheme 394)

1. Install the pressure regulator valve (1). Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). (Scheme 394)
2. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. (Scheme 394)
3. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot.
4. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. (Scheme 393) Install the transmission oil filter and pan. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
5. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 393

Scheme 394

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

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

(Scheme 395)

1. Install the rear servo assembly into the transmission case as follows: Accumulator spring (14). Selective pin (13). Servo spring retainer (12). Servo spring (11). Washer (10). Piston seal (9). Accumulator piston (8). Inner ring oil seal (7). Outer ring oil seal (1). Servo piston (2). Bottom retaining clip (3). Cover gasket (4). Cover (5). Cover Bolt (6).
2. Install the cover bolts and tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000) .
3. Install the transmission oil pan and filter. Lower vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000) .

Scheme 395

Apply the parking brake. Place the transmission into Neutral. Raise the vehicle. Disconnect the shift cable from the shift lever and the bracket (2). Remove the bolts (1) securing the shift cable bracket (2) to the transmission. (Scheme 396) Remove the shift cable bracket from the vehicle.

Install the shift cable bracket to the vehicle. Install the shift cable bracket bolts (1). (Scheme 396) Tighten the bolts to specification. See TORQUE SPECIFICATIONS. Install the shift cable to the bracket (2) and the lever. Lower the vehicle. Check the vehicle for proper operation. If adjustment of the cable is necessary, see SHIFT CABLE BRACKET under ADJUSTMENTS.

Scheme 396

1. Removal Procedure Place the gearshift lever to the PARK position. Raise and support 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 shift cable. (Scheme 397)
2. Pull back the white plastic cover (1) on the center connector. see scheme 9 Pull up on the center tabs of the lock button (2). see scheme 10 Ensure the gearshift lever remained in the PARK position for the best possible access to the E-clip. (Scheme 398) 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 that 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 399) Depress the tangs and remove the cable from the steering column bracket. Remove the bolt securing the cable support to the brace. (Scheme 400) 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 401) 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 399)
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-138559-S38941260632002041700000). Install the carpet and insulation around the driver's area. Install the instrument panel knee bolster. See REMOVAL & INSTALLATION in appropriate SHIFT INTERLOCK SYSTEMS article in AUTOMATIC TRANSMISSIONS.
4. Raise and support 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 397)
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 402)
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 12 Pull the White cover (3) on the cable end (1) back. see scheme 13 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 13 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 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

Scheme 402

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 397)
2. Locate the center connector on the shift cable. Pull back the White plastic cover (1) on the center connector. see scheme 9 Pull up on the center tabs of the lock button (2). see scheme 10
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 398)
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 403)
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 398) 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 397)
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 402)
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 13 Verify the White cover (1) conceals the Natural colored lock (2). see scheme 14 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-138559-S29628997942002041700000) under ADJUSTMENTS.

Scheme 403

1. Raise and support the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
2. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 405) 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 (4L60-E)»(ref-138559-S15601074902002041700000).
4. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift control solenoid. (Scheme 404)
5. Remove the TCC PWM solenoid retainer. Remove the TCC PWM solenoid to access one of the TCC solenoid retaining bolts. (Scheme 406)
6. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 364) Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 407)
7. Using the power piston seal protector and diaphragm retainer installer, release the pass-through electrical connector from the transmission case. (Scheme 408) Use the small end of the power piston seal protector and diaphragm 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.
8. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case.
9. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage, cracked, connectors, exposed wires and loose pins. (Scheme 404)

1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission. Install the pass-through electrical connector to the transmission case. (Scheme 408)
2. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. (Scheme 407) Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
3. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
4. Install the pressure control solenoid. (Scheme 364) Ensure the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
5. Install the TCC PWM solenoid to the control valve body. (Scheme 406) Install the TCC PWM solenoid retainer.
6. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift control solenoid. (Scheme 352)
7. 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 405)
8. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to the proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 404

Scheme 405

Scheme 406

Scheme 407

Scheme 408

Raise and support the vehicle. Remove the oil pan and the filter. See DRAINING & REFILLING under LUBRICATION. Disconnect the wiring harness if necessary. Remove the snap ring. (Scheme 409) Remove the plug. Remove the valve. Remove the spring.

Install the spring. Install the valve. Install the plug. (Scheme 409) Install the snap ring. Connect the wiring harness if necessary. Install the filter and oil pan. See DRAINING & REFILLING under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See LUBRICATION.

Scheme 409

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 410) Torque Converter Clutch Solenoid (1) Pressure Control Solenoid (2) Internal Wiring Harness (3) 2-3 Shift Control Solenoid (4) 1-2 Shift Control Solenoid (5) Transmission Fluid Pressure Manual Valve Position Switch (6) 3-2 Shift Control Solenoid (7) Torque Converter Clutch Pulse Width Modulation Solenoid (8)
2. Remove the fluid level indicator. Raise and support the vehicle. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure manual valve position switch (1), 1-2 shift control solenoid (2), 2-3 shift control solenoid (3), pressure control solenoid (4), TCC PWM solenoid (5), 3-2 shift control solenoid (6) and bracket bolt (2).
4. Remove the fluid indicator stop. (Scheme 411) Remove the fluid indicator bracket (1). 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.
5. Remove the TCC PWM solenoid (1) to access the TCC solenoid retaining bolts. (Scheme 406) Remove the TCC solenoid retaining bolts. (Scheme 412) Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body.
6. Reposition the harness to the side of the transmission case. (Scheme 408) Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 413) Remove the transmission fluid pressure switch. Inspect the transmission fluid pressure switch for damage or debris. (Scheme 414)
7. Remove the manual detent spring retaining bolt. Remove the manual detent spring. (Scheme 415) Inspect the manual detent spring for cracks or damage
8. Remove the remaining control valve body bolts. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. (Scheme 416)
9. If disassembly of the control valve body is necessary, see appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS.

Note. When installing bolts throughout this procedure, ensure to use the correct bolt size and length in the correct location as specified.

1. Install the 7 checkballs in the valve body. (Scheme 417) Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 416)
2. Verify the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). (Scheme 418) 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 419) Do not install the transmission fluid indicator stop bracket and bolt at this time.
3. Install but DO NOT tighten the control valve body bolts which retain only the valve body directly. (Scheme 420)
4. 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).
5. Install the manual detent spring. Install but DO NOT tighten the manual detent spring retaining bolt. (Scheme 415) Install the transmission fluid pressure switch. (Scheme 413) Install but DO NOT tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 413)
6. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten the control valve body bolts (in sequence) to 97 INCH lbs. (11 N.m). (Scheme 420)
7. Ensure the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
8. Install the TCC solenoid with a new O-ring seal to the valve body. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
9. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. Place the tab between the valve body and the pressure switch in the location shown (2). (Scheme 408) Press the harness into position on the valve body bolt bosses (1, 3).
10. Install the TCC PWM solenoid (1) to the control valve body. Install the TCC PWM solenoid retainer (2). (Scheme 406)
11. Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 411) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
12. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch (1). (Scheme 363) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
13. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 410

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

Scheme 419

Scheme 420

1. Remove the oil pan and filter. See «DRAINING & REFILLING»(ref-138559-S30587965752002041700000) under LUBRICATION.
2. Remove the Transmission Fluid Pressure (TFP) manual valve position switch bolts and switch. (Scheme 422) Remove the control valve assembly bolts and the fluid level indicator stop bracket.
3. Remove the lube oil pipe retainer (7) and the clamp. Remove the lube oil pipe (5). Remove the manual shaft detent spring assembly (3). (Scheme 360)
4. Remove the control valve assembly (2) which includes the following: The accumulator housing assembly. The control valve assembly to the spacer plate gasket. The spacer plate. The accumulator gasket.
5. Remove the manual valve (16) from the control valve body to prevent any damage. Inspect the manual valve for nicks and burrs. (Scheme 423)
6. Remove the spacer plate to case gasket from the case. The gasket may stick to the spacer plate. Remove the PWM screen from the case passages. Inspect the PWM screen for debris and damage.
7. Remove the 8 checkballs (9 checkballs for some transmissions).

1. Install the 8 checkballs (9 checkballs for some transmissions) into the control valve body. The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only. (Scheme 424)
2. To hold the checkballs in place, use assembly lubricant. Install the PWM screen into the control valve body.
3. Install the manual valve (16) into the control valve body. Install the control valve body gasket. Install the control valve body assembly. (Scheme 423)
4. Attach the manual valve to the detent lever while installing the control valve body assembly. Install the transmission fluid pressure manual valve position switch.
5. Install the transmission fluid pressure manual valve position switch bolts finger tight. Torque the bolts sequentially to specification. (Scheme 422)and «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).
6. Install the manual shaft detent roller and spring assembly (3) and bolts (2 and 4). Install the 2 wiring harness clips (1) and bolts (2). Install the wiring harness clip (1) and bolts (2). Install the lube oil pipe (5) with the short end into the control valve body. Install the lube oil pipe retainer (7) and the bolt (6). (Scheme 360)
7. Install the remaining control valve body bolts and tighten in the order shown. (Scheme 421) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138559-S38941260632002041700000).

Scheme 421

Scheme 422

Scheme 423

Scheme 424

Raise and support the vehicle. Remove the electrical connector from the speed sensor. Remove the bolt. (Scheme 425) Remove the speed sensor and the O-ring seal. Inspect the seal and the transmission case. Replace the seal, if necessary.

Install the speed sensor and the O-ring seal into the transmission. (Scheme 425) Install the bolt and tighten to specification. See TORQUE SPECIFICATIONS. Install the electrical connector to the speed sensor. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See LUBRICATION.

Scheme 425

Raise the vehicle. Disconnect the input speed sensor (1) electrical connector. Remove the input speed sensor bolt. Remove the input speed sensor (1) and the bracket assembly from the case. (Scheme 426) Inspect the vehicle speed sensor assembly (1) for any evidence of damage.

Lubricate the input speed sensor seal with automatic transmission fluid. Install the input speed sensor (1) and the bracket assembly. (Scheme 426) Install and tighten the bolt to specification. See TORQUE SPECIFICATIONS. Connect the input speed sensor electrical connector. Lower the vehicle.

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

Raise and support the vehicle. Disconnect the output speed sensor (2) electrical connector. (Scheme 426) Remove the output speed sensor bolt. Remove the output speed sensor (2) and the bracket assembly from the case. Inspect the output speed sensor assembly (2) for any evidence of damage.

Lubricate the output speed sensor seal with ATF. Install the output speed sensor (2) and the bracket assembly. (Scheme 426) Install and tighten the bolt to specification. See TORQUE SPECIFICATIONS. Connect the output speed sensor electrical connector. Lower the vehicle.

Scheme 426

Remove the vent hose clip. Remove the vent hose from the transmission vent. (Scheme 427)

Install the vent hose to the transmission. Install the vent hose to the clip. Install the bolt and the clamp. (Scheme 427) Tighten the bolt to specification. See TORQUE SPECIFICATIONS.

Scheme 427

1. Raise and support the vehicle. Remove the oil pan bolt located below and to the left of the 2-4 servo cover. Install the servo cover depressor to the oil pan rail. Tighten the bolt on the servo cover depressor to compress the servo cover. (Scheme 428)
2. Remove the servo cover retaining ring. (Scheme 429) Loosen the bolt on the servo cover depressor to release tension on the servo cover. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. (Scheme 430)
3. Remove the 2-4 servo assembly from the transmission.
4. Inspect the 4th apply piston, the 2-4 servo converter, 2nd apply piston, and the piston inner housing for cracks, scoring, burrs and nicks. (Scheme 431)

Assembly & Installation

1. Install new seals on all the 2-4 servo pistons and the cover. (Scheme 434)
2. Install the servo cushion spring and the cushion spring retainer in the 2nd apply piston. Use the Piston Remover to compress the second apply piston. Install the second apply piston retaining ring. (Scheme 433)
3. Install the following parts: 2nd apply piston pin. Spring. Washer. Retainer ring.
4. Install the following parts: Servo return spring. 4th apply piston. (Scheme 432)and (Scheme 433).
5. Lower vehicle. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138559-S42529332262002041700000).

Scheme 428

Scheme 429

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

Scheme 436

Scheme 437

Scheme 438