Automatic Transmission - 4L60-E/4L65-E (Introduction, Service & Replacement): Other Chevrolet Silverado 3500

Range Reference (M30/M32)

Range Reference Table

Range Reference (M33 Only)

Range Reference Table

Shift Solenoid Valve State and Gear Ratio

Shift Solenoid Valve State and Gear Ratio 4L60-E

Shift Speed (M30/M32)

Shift Speed

Shift Speed (M33 Only)

Shift Speed (M33 Only)

Transmission Range Switch Logic

Transmission Range Switch Logic

Line Pressure

Line Pressure (4L60-E)

Component Resistance (M30/M32)

Component Resistance (M30/M32)

Component Resistance (M33 Only)

Component Resistance (M33 Only)

Tools Required

J 41364-A Park Neutral Switch Aligner. See Special Tools and Equipment .

Scheme 557

Scheme 558

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-184221-S09162167182005082200000) in Driveline/Axle.
4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
5. Disconnect the park/neutral position (PNP) switch electrical connector (2).
6. Remove the manual shaft lever nut.
7. Remove the transmission control lever from the manual shaft.
8. Remove the PNP switch bolts.
9. Remove the PNP switch from the manual shaft. If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs.

Scheme 559

1. Install the PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats.
2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission.
3. Install the PNP switch bolts finger tight.
4. Install 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.
5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time.
7. Install the transmission control lever to the manual shaft with the nut. Tighten: Tighten the nut to 25 N.m (18 lb ft).
8. Connect the PNP switch electrical connector (2).
9. If equipped with 4WD, install the front propeller shaft. Refer to «Propeller Shaft Replacement - Front»(ref-184221-S09162167182005082200000) in Driveline/Axle.
10. Lower the vehicle.
11. Check the switch for proper operation. The engine must start in the park (P) or neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch.

J 29714-A Servo Cover Depressor. See Special Tools and Equipment .

Scheme 560

Scheme 561

1. Remove the exhaust pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-184230-S38273361172005082200000) in Engine Exhaust.
2. Remove the heat shield bolts.
3. Remove the heat shield.
4. Remove the oil pan bolt below the servo.
5. Install the J 29714-A .
6. Tighten the bolt on J 29714-A in order to compress the servo cover.
7. Remove the servo cover ring.
8. Remove the J 29714-A .
9. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover.
10. Remove the 2-4 servo.
11. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects: Cracks Scoring Burrs and nicks

Scheme 562

1. Install NEW seals onto the servo pistons and the servo cover.
2. Install the 2-4 servo.
3. Install the J 29714-A .
4. Tighten the bolt on J 29714-A in order to compress the servo cover.
5. Install the servo cover ring.
6. Remove the J 29714-A .
7. Install the oil pan bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
8. Install the heat shield and bolts. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
9. Install the exhaust pipe. Refer to «Exhaust Manifold Pipe Replacement (6.0L, 6.6L, and 8.1L Engines)»(ref-184230-S38273361172005082200000) in Engine Exhaust.
10. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184197-S28503790432005082200000) .

Scheme 563

1. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .
2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring.
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).
5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
6. Remove the pressure regulator valve (1).

Scheme 564

1. Install the pressure regulator valve (1).
2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5).
4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover.
5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot.
6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
7. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .

Scheme 565

Scheme 566

Scheme 567

Scheme 568

1. Unlock the transmission oil level indicator.
2. Remove the transmission oil level indicator.
3. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
4. Support the transmission using a suitable jack.
5. Remove the transmission mount nut.
6. Remove the transmission crossmember bolts/nuts.
7. Remove the transmission crossmember.
8. Loosen the left exhaust pipe nuts.
9. Loosen the right exhaust pipe nuts.
10. Remove the insulator nuts and insulator from the bracket.
11. Remove the exhaust pipe hanger bracket bolts and bracket.
12. Lower the transmission slightly.
13. Disconnect the transmission oil cooler lines. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) .
14. Plug the transmission oil cooler line fittings.
15. Remove the indicator tube nut.
16. Remove the indicator tube bolt, if equipped with RPO HP2.
17. Remove the oil level indicator tube.
18. Remove the seal from the transmission, if necessary.
19. Remove the oil level indicator tube, if equipped with RPO HP2.
20. Remove the seal from the transmission, if necessary.

Scheme 569

1. Install a NEW seal to the indicator tube.
2. Install the oil level indicator tube, if equipped with RPO HP2.
3. Install a NEW seal to the indicator tube.
4. Install the oil level indicator tube.
5. Install the indicator tube bolt, if equipped with RPO HP2. Tighten: Tighten the bolt to 18 N.m (13 lb ft).
6. Install the indicator tube nut. Tighten: Tighten the nut to 18 N.m (13 lb ft).
7. Remove the plugs from the transmission oil cooler line fittings.
8. Connect the transmission oil cooler lines. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) .
9. Install the exhaust pipe hanger bracket and bolts. Tighten: Tighten the bolts to 17 N.m (12 lb ft).
10. Instal the insulator and nuts to the bracket. Tighten: Tighten the nuts to 17 N.m (12 lb ft).
11. Tighten the right exhaust pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
12. Tighten the left exhaust pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
13. Install the transmission crossmember.
14. Install the transmission crossmember bolts/nuts. Tighten: Tighten the bolts/nuts to 95 N.m (70 lb ft).
15. Install the transmission mount nut. Tighten: Tighten the nut to 50 N.m (37 lb ft).
16. Remove the support from the transmission.
17. Lower the vehicle.
18. Install the transmission oil level indicator.
19. Lock the transmission oil level indicator.

Scheme 570

1. Remove the auxiliary pump. Refer to «Auxiliary Pump Replacement (5.3L Engine w/RPO HP2)»(ref-184202-S13551838752005082200000) .
2. Remove the push-on clip from the auxiliary pump.
3. Rotate the filter upward and separate the filter from the pump.

1. J 43911 Selector Shaft Seal Remover. See «Special Tools and Equipment»(ref-184202-S17623355442005082200000) .
2. J 43909 Selector Shaft Seal Installer. See «Special Tools and Equipment»(ref-184202-S17623355442005082200000) .

Scheme 571

1. Remove the park/neutral position (PNP) switch. Refer to «Park/Neutral Position Switch Replacement»(ref-184202-S15976129972005082200000) .
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 removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure 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 572

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. Obtain J 43909 and 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 bore until it is seated at the bottom of the bore.
4. Install the PNP switch. Refer to «Park/Neutral Position Switch Replacement»(ref-184202-S15976129972005082200000) .
5. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184197-S28503790432005082200000) .

Scheme 573

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

1. Ensure that removal of the valve body is necessary before proceeding. IMPORTANT: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) The pressure control solenoid (2) The internal wiring harness (3) The 2-3 shift solenoid (4) The 1-2 shift solenoid (5) The transmission fluid pressure manual valve position switch (6) The 3-2 shift solenoid (7) The torque converter clutch pulse width modulation (TCC PWM) solenoid (8)
2. Remove the fluid level indicator.
3. Remove the auxiliary pump, if equipped with RPO HP2. Refer to «Auxiliary Pump Replacement (5.3L Engine w/RPO HP2)»(ref-184202-S13551838752005082200000) .
4. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .
5. Disconnect the internal wiring harness electrical connectors from the following components: The transmission fluid pressure manual valve position switch (1) The 1-2 shift solenoid (2) The 2-3 shift solenoid (3) The pressure control solenoid (4) The TCC PWM solenoid (5) The 3-2 shift solenoid (6)
6. Remove the fluid indicator stop bracket bolt (2).
7. Remove the fluid indicator bracket (1).
8. 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.
9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid bolts.
10. Remove the TCC solenoid bolts.
11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the valve body.
12. Reposition the harness to the side of the transmission case.
13. Remove the valve body bolts which retain the transmission fluid pressure switch to the valve body.
14. Remove the transmission fluid pressure switch.
15. Inspect the transmission fluid pressure switch for damage or debris.
16. Remove the manual detent spring bolt.
17. Remove the manual detent spring.
18. Inspect the manual detent spring for cracks or damage.
19. Remove the remaining valve body bolts.
20. Carefully lower the valve body from the transmission case while simultaneously disconnecting the manual valve link.
21. Remove the seven valve body check balls.
22. Remove the accumulator cover bolts (58, 59).
23. Remove the 1-2 accumulator cover and pin assembly (57).
24. Remove the spacer plate support bolts (77).
25. Remove the spacer plate support (53).
26. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard the gaskets. Do not reuse.

Scheme 579

1. Install a NEW valve body gasket (52), the valve body spacer plate (48) and a NEW case gasket (47).
2. Install the spacer plate support (53) and bolts (77). Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the 1-2 accumulator cover and pin assembly (57).
4. Install the 1-2 accumulator cover bolts (58, 59). Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the seven check Balls into the valve body.
6. Install the valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve.
7. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2).
8. 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.
9. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the 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)
10. Install the manual detent spring.
11. Install but do not tighten the manual detent spring bolt.
12. Install the transmission fluid pressure switch.
13. Install but do not tighten the valve body bolts which retain the transmission fluid pressure switch to the valve body.
14. Tighten the valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten: Tighten the bolts in the sequence shown to 11 N.m (97 lb in).
15. Ensure that the manual detent spring is aligned properly with the detent lever. Tighten: Tighten the bolt to 11 N.m (97 lb in).
16. Install the TCC solenoid with a NEW O-ring seal to the valve body.
17. Install the TCC solenoid bolts. Tighten: Tighten the bolts to 11 N.m (97 lb in).
18. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit.
19. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3).
20. Install the TCC PWM solenoid (1) to the valve body.
21. Install the TCC PWM solenoid retainer (2).
22. Install the transmission fluid indicator stop bracket (1) and bolt (2). Tighten: Tighten the bolt to 11 N.m (97 lb in).
23. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch (1) The 1-2 shift solenoid (2) The 2-3 shift solenoid (3) The pressure control solenoid (4) The TCC PWM solenoid (5) The 3-2 shift solenoid (6)
24. Install the auxiliary pump, if equipped with RPO HP2. Refer to «Auxiliary Pump Replacement (5.3L Engine w/RPO HP2)»(ref-184202-S13551838752005082200000) .
25. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .

Scheme 580

1. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .
2. Remove the 1-2 accumulator, if necessary. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-184202-S01462896382005082200000) .
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) torque converter clutch pulse width modulation (TCC PWM) solenoid (5) 3-2 control solenoid (6)
4. Remove the pressure control solenoid retainer bolt (364A) and retainer (378).
5. Remove the pressure control solenoid (377).
6. Remove the 1-2 shift solenoid retainer (395) and the 1-2 shift solenoid (267A).
7. Remove the 2-3 shift solenoid retainer (395) and the 2-3 shift solenoid (367A).
8. Remove the 3-2 control solenoid retainer (395) and the 3-2 control solenoid (394).

Scheme 581

1. Install the 3-2 control solenoid (394) and the 3-2 control solenoid retainer (395).
2. Install the 2-3 shift solenoid (367A) and the 2-3 shift solenoid retainer (395).
3. Install the 1-2 shift solenoid (267A) and the 1-2 shift solenoid retainer (395).
4. Install the pressure control solenoid (377).
5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten: Tighten the bolt to 11 N.m (97 lb in).
6. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) TCC PWM solenoid (5) 3-2 control solenoid (6)
7. Install the 1-2 accumulator, if necessary. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-184202-S01462896382005082200000) .
8. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .

J 28458 Seal Protector Retainer Installer. See Special Tools and Equipment .

Scheme 582

Scheme 583

1. Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .
2. Disconnect the transmission harness 20-way connector (1) from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector.
3. Remove the 1-2 accumulator. Do not remove the spacer plate. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-184202-S01462896382005082200000) .
4. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) Torque converter clutch pulse width modulation (TCC PWM) solenoid (5) 3-2 control solenoid (6)
5. Remove the TCC PWM solenoid retainer.
6. Remove the TCC PWM solenoid in order to access one of the TCC solenoid bolts.
7. Remove the pressure control solenoid retainer bolt (364A) and retainer (378).
8. Remove the pressure control solenoid (377).
9. Remove the TCC solenoid bolts and the valve body bolts which retain the internal wiring harness.
10. Using J 28458 , release the pass-through electrical connector from the transmission case. Use the small end of the J 28458 over the top of the connector. Twist in order to release the four tabs retaining the connector. Pull the harness connector down through the transmission case.
11. Remove the TCC solenoid (with O-ring seal) and wiring harness.
12. Inspect the TCC solenoid and wiring harness for the following defects: Damage Cracked connectors Exposed wires Loose pins

Scheme 584

Scheme 585

1. Install the wiring harness and TCC solenoid with a new O-ring seal to the transmission.
2. Install the pass-through electrical connector to the transmission case.
3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid bolts. Tighten: Tighten the control valve body bolts to 11 N.m (97 lb in). Tighten the TCC solenoid bolts to 11 N.m (97 lb in).
4. Install the pressure control solenoid (377).
5. Install the pressure control solenoid retainer (378) and retainer bolt (364A). Tighten: Tighten the bolt to 11 N.m (97 lb in).
6. Install the TCC PWM solenoid to the control valve body.
7. Install the TCC PWM solenoid retainer.
8. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) TCC PWM solenoid (5) 3-2 control solenoid (6)
9. Install the 1-2 accumulator. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-184202-S01462896382005082200000) .
10. Connect the transmission harness 20-way connector (1) to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down.
11. Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184202-S21897449202005082200000) .

J 46093 Rotor and Flexplate Holding Tool

Scheme 586

1. Remove the transmission. Refer to «Transmission Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184202-S01986572282005082200000) or «Transmission Replacement (5.3L Engine w/RPO HP2)»(ref-184202-S16799127802005082200000) . NOTE: Refer to «Fastener Notice»(ref-184123-S11449185592005082200000) in Cautions and Notices.
2. Install the J 46093 (1) and bolts. The flange of the J 46093 should locate into the hole in the flexplate. Use two M10 1.5 x 40 mm bolts for proper tool operation. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Remove the flexplate bolts.
4. Remove the flexplate.

Scheme 587

1. Install the flexplate.
2. Install the flexplate bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
3. Remove the J 46093 (1) and bolts.
4. Install the transmission. Refer to «Transmission Replacement (4.8L, 5.3L, and 6.0L Engines)»(ref-184202-S01986572282005082200000) or «Transmission Replacement (5.3L Engine w/RPO HP2)»(ref-184202-S16799127802005082200000) .

J 21366 Converter Holding Strap

J 21366 Converter Holding Strap

Scheme 588

Scheme 589

Scheme 590

Scheme 591

1. Disconnect the energy storage box (ESB). Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-184144-S17357825682005082200000) in Engine Electrical.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
3. Remove the intake manifold. Refer to «Intake Manifold Replacement»(ref-184187-S14258848172005082200000) .
4. Remove the 3-phase cable bracket cover bolt (1).
5. Remove the starter/generator control module (SGCM) cover bolts and cover.
6. Remove the 3-phase cable nuts.
7. Remove the 3-phase cable from the SGCM studs.
8. From under the hood, remove the transmission fill tube bolt. Reposition the fill tube.
9. Drain the cooling system and engine block. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
10. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
11. Drain the transmission fluid.
12. Remove the transfer case, if equipped. Refer to «Transfer Case Assembly Replacement»(ref-184196-S20622591852005082200000) in Transfer Case - NVG 261-NP2, or «Transfer Case Assembly Replacement»(ref-184161-S03457298082005082200000) in Transfer Case - NVG 246-NP8.
13. Remove the rear propeller shaft, if vehicle is a 2-wheel drive (2WD). Refer to «Propeller Shaft Replacement - One Piece»(ref-184221-S28715217102005082200000) in Propeller Shaft.
14. If vehicle is a 2WD, support the engine with a suitable adjustable jack. IMPORTANT: If the vehicle is a 2WD, it is necessary to remove the crossbar, in order to remove the transmission.
15. If vehicle is a 2WD, remove the crossbar bolts and bar.
16. Support the transmission with a transmission jack.
17. Remove the transmission mount nuts.
18. Remove the transmission support bolts and nuts.
19. Raise the transmission slightly and remove the transmission support.
20. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(ref-184230-S11777245742005082200000) or «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(ref-184230-S34445979752005082200000) or «Catalytic Converter Replacement (6.6L Engine)»(ref-184230-S34928714002005082200000) in Engine Exhaust.
21. Lower the transmission slightly, in order to gain access to the top of the transmission.
22. Remove the transmission heat shield bolts and shield.
23. Remove the connector position assurance (CPA) retainer.
24. Disconnect the park/neutral position (PNP) switch electrical connector (2).
25. Disconnect the transmission harness 20-way connector (1) from the internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector.
26. If vehicle is a 2WD, disconnect the vehicle speed sensor (VSS) (2).
27. Remove the bolt that secures the fuel line bracket to the left side of the transmission.
28. Reposition the harness out of the way.
29. Disconnect the range selector cable end (2) from the transmission range selector lever ball stud (1).
30. Remove the transmission range selector cable bracket bolts (1).
31. Reposition the selector cable bracket (2) and cable out of the way.
32. Remove the driver side exhaust heat shield nuts (2).
33. Remove the driver side exhaust heat shield (1).
34. Remove the thermal bypass hose bolt.
35. Reposition the thermal bypass hose clamp.
36. Remove the thermal bypass hose from the fitting.
37. Remove the coolant inlet pipe to stator bolt (4).
38. Reposition the inlet pipe (3) out of the way.
39. Remove the driver side closeout cover bolt and cover.
40. Remove the passenger side closeout cover bolt and cover.
41. Remove the engine shield bolts and shield, if necessary.
42. Remove the torque converter bolts.
43. Disconnect the transmission oil cooler lines from the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) .
44. Plug the transmission oil cooler lines and fittings.
45. Lower the transmission, in order to access the 3-phase cable cover.
46. Remove the 3-phase cable cover nuts (3).
47. Remove the 3-phase cable nuts (4).
48. Remove the 3-phase cable from the stator studs.
49. Position the 3-phase cable up and out of the way, in order to access the fill tube bolt.
50. Remove the fuel line bracket nut and bracket from the upper left bellhousing stud.
51. Remove the transmission vent hose bracket nut and bracket from the top bellhousing stud.
52. Remove the vent hose from the transmission.
53. Remove the transmission studs (1) and bolts (2) to the engine.
54. Remove the transmission nuts to the engine.
55. Pull the transmission straight back in order to disengage the torque converter.
56. Once the transmission is pulled back far enough, install J 21366 onto the bell housing in order to retain the torque converter.
57. Once the transmission is far enough back, remove the driver side stator stud.
58. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.
59. Flush the transmission oil cooler and cooling lines if necessary. Refer to «Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096)»(ref-184197-S08476308162005082200000) or «Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A)»(ref-184197-S42793761832005082200000) .

Scheme 592

Scheme 593

Scheme 594

Scheme 595

1. Install the transmission to the vehicle while simultaneously installing the fluid level indicator tube.
2. Once the transmission is half way installed, install the driver side stator stud. Tighten: Tighten the stud to 16 N.m (12 lb ft).
3. Once the transmission is half way installed, remove J 21366 from the bellhousing.
4. Slide the transmission forward in order to engage the torque converter.
5. Install the transmission nuts to the engine. Tighten: Tighten the nuts to 12 N.m (106 lb in).
6. Install the transmission studs (1) and bolts (2) to the engine. Tighten: Tighten the bolts and studs to 50 N.m (37 lb ft).
7. Install the vent hose to the transmission.
8. Install the transmission vent hose bracket and nut to the top bellhousing stud. Tighten: Tighten the nut to 12 N.m (106 lb in).
9. Install the fuel line bracket and nut to the upper left bellhousing stud. Tighten: Tighten the nut to 12 N.m (106 lb in).
10. Position the 3-phase cable to the stator studs.
11. Install the 3-phase cable nuts (4). Tighten: Tighten the nuts a first pass to 14 N.m (10 lb ft). Tighten the nuts a final pass to 14 N.m (10 lb ft).
12. Install the 3-phase cable cover and nuts (3). Tighten: Tighten the nuts to 9 N.m (80 lb in).
13. Raise the transmission to a level position.
14. Remove the torque converter access plug.
15. Rotate the torque converter in order to align the converter bolt holes with the flexplate holes.
16. Install the torque converter bolts. Tighten: Tighten the bolts to 63 N.m (46 lb ft).
17. Install the torque converter access plug.
18. Install the engine shield and bolts, if necessary. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
19. Install the passenger side closeout cover and bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
20. Install the driver side closeout cover and bolt. Tighten: Tighten the bolt to 12 N.m (106 lb in).
21. Position the inlet pipe (3) to the stator.
22. Install the coolant inlet pipe to stator bolt (4). Tighten: Tighten the bolt to 9 N.m (80 lb in).
23. Install the thermal bypass hose to the fitting.
24. Position the thermal bypass hose clamp. IMPORTANT: Ensure that there is a O-ring seal on the bypass hose end that attaches to the transmission.
25. Install the thermal bypass hose bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
26. Install the driver side exhaust heat shield (1).
27. Install the driver side exhaust heat shield nuts (2). Tighten: Tighten the nuts to 9 N.m (80 lb in).
28. Position the selector cable bracket (2) and cable.
29. Install the transmission range selector cable bracket bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
30. Connect the range selector cable end (2) to the transmission range selector lever ball stud (1).
31. Position the harness to the transmission.
32. Install the bolt that secures the fuel line bracket to the left side of the transmission. Tighten: Tighten the bolt to 10 N.m (89 lb in).
33. If vehicle is a 2WD, connect the VSS (2).
34. Connect the transmission harness 20-way connector (1) to the internal harness pass-through connector.
35. Connect the PNP switch electrical connector (2).
36. Install the CPA retainer.
37. Install the transmission heat shield and bolts. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
38. Raise the transmission slightly.
39. Install the catalytic converter. Refer to «Catalytic Converter Replacement (4.3L, 4.8L, and 5.3L Engines)»(ref-184230-S11777245742005082200000) or «Catalytic Converter Replacement (6.0L and 8.1L Engines)»(ref-184230-S34445979752005082200000) or «Catalytic Converter Replacement (6.6L Engine)»(ref-184230-S34928714002005082200000) in Engine Exhaust.
40. Install the transmission support.
41. Install the transmission support bolts and nuts. Tighten: Tighten the bolts to 70 N.m (50 lb ft).
42. Lower the transmission onto the support.
43. Install the transmission mount nuts. Tighten: Tighten the nuts to 40 N.m (29 lb ft).
44. Remove the support from the transmission.
45. If vehicle is a 2WD, remove the support from the engine.
46. If vehicle is a 2WD, install the crossbar bolts and bar. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
47. If vehicle is a 2WD, install the rear propeller shaft. Refer to «Propeller Shaft Replacement - One Piece»(ref-184221-S28715217102005082200000) in Propeller Shaft.
48. Remove the plugs from the transmission oil cooler lines and fittings.
49. Connect the transmission oil cooler lines to the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) .
50. Install the transfer case, if equipped. Refer to «Transfer Case Assembly Replacement»(ref-184196-S20622591852005082200000) in Transfer Case - NVG 261-NP2, or «Transfer Case Assembly Replacement»(ref-184161-S03457298082005082200000) in Transfer Case - NVG 246-NP8.
51. From under the hood, position the fill tube. Install the fill tube bolt. Tighten: Tighten the bolt to 18 N.m (13 lb ft).
52. Install the 3-phase cable to the SGCM studs.
53. Install the 3-phase cable nuts. Tighten: Tighten the nuts to 15 N.m (11 lb ft).
54. Install the SGCM cover and bolts. Tighten: Tighten the bolts to 9 N.m (80 lb in).
55. Install the 3-phase cable bracket cover bolt (1). Tighten: Tighten the bolt to 9 N.m (80 lb in).
56. Install the intake manifold. Refer to «Intake Manifold Replacement»(ref-184187-S14258848172005082200000) .
57. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure (Single Battery)»(ref-184144-S12006988322005082200000) or «Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery)»(ref-184144-S01033869922005082200000) in Engine Electrical.
58. Refill the cooling system and engine block. Refer to «Draining and Filling Cooling System (with HP2)»(ref-184167-S24141861562005082200000) or «Draining and Filling Cooling System (without HP2)»(ref-184167-S08637076072005082200000) in Engine Cooling.
59. Connect the ESB. Refer to «Energy Storage Box (ESB) Service Disconnect/Connect (5.3L Engine w/RPO HP2)»(ref-184144-S17357825682005082200000) in Engine Electrical.
60. Fill the transmission to the correct capacity using DEXRON® III transmission fluid. Refer to «Capacities - Approximate Fluid»(ref-184199-S32642491652005082200000) in Maintenance and Lubrication.

How to Use This Section

This section provides the following information

1. General diagnosis information on transmissions
2. Procedures for diagnosing the Hydra-matic transmission

When you diagnose any condition of the Hydra-matic transmission, begin with A Diagnostic Starting Point. This procedure indicates the proper path of diagnosing the transmission by describing the basic checks. This procedure will then refer you to the locations of specific checks. After you have determined the cause of a condition, refer to Repair Instructions for repair procedures. If the faulty component is not serviceable without removing the transmission from the vehicle, refer to Unit Repair for repair information.

Basic Knowledge

Note. Do not, under any circumstances, attempt to diagnose a powertrain condition without basic knowledge of this powertrain. If you perform diagnostic procedures without this basic knowledge, you may incorrectly diagnose the condition or damage the powertrain components.

You must be familiar with some basic electronics in order to use this section of the service manual. You should also be able to use the following special tools

1. A digital multimeter (DMM)
2. A circuit tester
3. Jumper wires or leads
4. A line pressure gage set

Transmission Adaptive Functions

The 4L60-E transmission utilizes a line pressure control system during upshifts to compensate for the normal wear of transmission components. By adjusting the line pressure, the PCM can maintain acceptable transmission shift times. This process is known as "adaptive learning" or "shift adapts" and is similar to the closed loop fuel control system used for the engine.

In order for the PCM to perform a "shift adapt," it must first identify if an upshift is acceptable to analyze. For example, upshifts that occur during cycling of the A/C compressor or under extreme throttle changes could cause the PCM to incorrectly adjust line pressure. When an upshift is initiated, a number of contingencies, such as throttle position, transmission temperature, and vehicle speed, are checked in order to determine if the actual shift time is valid to compare to a calibrated desired shift time. If all the contingencies are met during the entire shift, then the shift is considered valid and the adapt function may be utilized if necessary.

Once an adaptable shift is identified, the PCM compares the actual shift time to the desired shift time and calculates the difference between them. This difference is known as the shift error. The actual shift time is determined from the time that the PCM commands the shift to the start of the engine RPM drop initiated by the shift. If the actual shift time is longer than the calibrated desired shift time, a soft feel or slow engagement, then the PCM decreases current to the pressure control (PC) solenoid in order to increase line pressure for the next, same, upshift under identical conditions. If the actual shift time is shorter than the calibrated desired shift time, a firm engagement, then the PCM increases current to the PC solenoid in order to decrease line pressure for the next, same, upshift under identical conditions.

The purpose of the adapt function is to automatically compensate the shift quality for the various vehicle shift control systems. It is a continuous process that will help to maintain optimal shift quality throughout the life of the vehicle.

Clearing Transmission Adaptive Pressure (TAP)

Transmission adaptive pressure (TAP) information is displayed and may be reset using a scan tool.

The adapt function is a feature of the PCM that either adds or subtracts line pressure from a calibrated base line pressure in order to compensate for normal transmission wear. The TAP information is divided into 13 units, called cells. The cells are numbered 4 through 16. Each cell represents a given torque range. TAP cell 4 is the lowest adaptable torque range and TAP cell 16 is the highest adaptable torque range. It is normal for TAP cell values to display zero or negative numbers. This indicates that the PCM has adjusted line pressure at or below the calibrated base line pressure.

Updating TAP information is a learning function of the PCM designed to maintain acceptable shift times. It is not recommended that TAP information be reset unless one of the following repairs has been made

1. Transmission overhaul or replacement
2. Repair or replacement of an apply or release component, clutch, band, piston, servo
3. Repair or replacement of a component or assembly which directly affects line pressure

Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the PCM will need to relearn TAP values. Transmission performance may be affected as new TAPs are learned. Learning can only take place when the PCM has determined that an acceptable shift has occurred. The PCM must also relearn TAP values if it is replaced.

Transmission Indicators and Messages

The following transmission-related indicators and messages may be displayed on the instrument panel cluster (IPC). For a complete listing and description of all vehicle indicators and messages, refer to Indicator/Warning Message Description and Operation in Instrument Panel, Gages, and Console.

1-2 and 2-3 Shift Solenoid Valves

The 1-2 and 2-3 shift solenoid valves (also called A and B solenoids) are identical devices that control the movement of the 1-2 and 2-3 shift valves. The 3-4 shift valve is not directly controlled by a shift solenoid. The solenoids are normally-open exhaust valves that work in 4 combinations to shift the transmission into different gears.

Scheme 596

The powertrain control module (PCM) energizes each solenoid by grounding the solenoid through an internal quad driver. This sends current through the coil winding in the solenoid and moves the internal plunger out of the exhaust position. When ON, the solenoid redirects fluid to move a shift valve.

The PCM-controlled shift solenoids eliminate the need for TV and governor pressures to control shift valve operation.

The 1-2 and 2-3 shift solenoid valves (also called A and B solenoids) are identical devices that control the movement of the 1-2 and 2-3 shift valves. The 3-4 shift valve is not directly controlled by a shift solenoid. The solenoids are normally-open exhaust valves that work in 4 combinations to shift the transmission into different gears.

The powertrain control module (PCM) energizes each solenoid by grounding the solenoid through an internal quad driver. This sends current through the coil winding in the solenoid and moves the internal plunger out of the exhaust position. When ON, the solenoid redirects fluid to move a shift valve.

The PCM-controlled shift solenoids eliminate the need for TV and governor pressures to control shift valve operation.

Transmission Pressure Control Solenoid

The transmission pressure control solenoid is an electronic pressure regulator that controls pressure based on the current flow through its coil winding. The magnetic field produced by the coil moves the solenoid's internal valve which varies pressure to the pressure regulator valve.

The PCM controls the pressure control solenoid by commanding current between 0.1-1.1 amps. This changes the duty cycle of the solenoid, which can range between 5-95 percent, typically less than 60 percent. High amperage (1.1 amps) corresponds to minimum line pressure, and low amperage (0.1 amp) corresponds to maximum line pressure, if the solenoid loses power, the transmission defaults to maximum line pressure.

The PCM commands the line pressure values, using inputs such as engine speed and throttle position sensor voltage.

The pressure control solenoid takes the place of the throttle valve or the vacuum modulator that was used on past model transmissions.

Transmission Range Switch

The transmission range (TR) switch is part of the park/neutral position (PNP) and backup lamp switch assembly, which is externally mounted on the transmission manual shaft. The TR switch contains four internal switches that indicate the transmission gear range selector lever position. The powertrain control module (PCM) supplies ignition voltage to each switch circuit. As the gear range selector lever is moved, the state of each switch may change, causing the circuit to open or close. An open circuit or switch indicates a high voltage signal. A closed circuit or switch indicates a low voltage signal. The PCM detects the selected gear range by deciphering the combination of the voltage signals. The PCM compares the actual voltage combination of the switch signals to a TR switch combination chart stored in memory.

Tow/Haul Mode Switch

Tow/Haul mode enables the operator to achieve enhanced shift performance when towing or hauling a load. When tow/haul mode is selected, the tow/haul switch input signal to the body control module (BCM) is momentarily toggled to zero volts. This signals the powertrain control module (PCM) to extend the length of time between upshifts and increase transmission line pressure. Cycling the tow/haul switch again, or cycling the ignition switch disables tow/haul mode and returns the transmission to a normal shift pattern.

Scheme 597

The transmission electrical connector is an important part of the transmission operating system. Any interference with the electrical connection can cause the transmission to set diagnostic trouble codes or affect proper operation.

The following items can affect the electrical connection

1. Bent pins in the connector from rough handling during connection and disconnection
2. Wires backing away from the pins or coming uncrimped, in either the internal or the external wiring harness
3. Dirt contamination entering the connector when disconnected
4. Pins in the internal wiring connector backing out of the connector or pushed out of the connector during reconnection
5. Transmission fluid leaking into the connector, wicking up into the external wiring harness and degrading the wire insulation
6. Moisture intrusion in the connector
7. Low pin retention in the external connector from excessive connection and disconnection of the wiring connector assembly
8. Pin corrosion from contamination
9. Damaged connector assembly

Remember the following points

1. In order to remove the connector, squeeze the two tabs toward each other and pull straight up without pulling by the wires.
2. Limit twisting or wiggling the connector during removal. Bent pins can occur.
3. Do not pry the connector off with a screwdriver or other tool.
4. Visually inspect the seals to ensure that they are not damaged during handling.
5. In order to reinstall the external wiring connector, first orient the pins by lining up the arrows on each half of the connector. Push the connector straight down into the transmission without twisting or angling the mating parts.
6. The connector should click into place with a positive feel and/or noise.
7. Whenever the transmission external wiring connector is disconnected from the internal harness and the engine is operating, DTCs will set. Clear these DTCs after reconnecting the external connector.