Automatic Transmission - 4L60-E/4L65-E - Overhaul: Removal & Installation Chevrolet Silverado 3500

Installation Procedure

1. Install the J 8763-02 onto the transmission.
2. Install the J 8763-02 into the base.

Removal Procedure

1. Remove the converter housing bolts (94). Use the J 41510 .
2. Remove the converter housing (102).

1. Install the J 29714-A .
2. Tighten the J 29714-A bolt to compress the servo cover.
3. Remove the servo cover retaining ring (29) and the J 29714-A .
4. Remove the servo cover (28) and O-ring seal (27). If the servo cover seems to be hung up on the seal, cut and remove the O-ring seal before removing the cover.
5. Remove the 2-4 servo assembly.

1. Remove the sensor retaining bolt (35).
2. Remove the speed sensor (36) and O-ring seal (37).
3. Remove the case extension bolts (32).
4. Remove the case extension (31) and the case extension to case seal (30).
5. Remove the output shaft sleeve (690) and the output shaft O-ring seal (691). Not all models use an output shaft sleeve (690) and O-ring seal (691).
6. Install the J 29837-A . If the J 29837-A is not used, the output shaft (687) may fall free when the input carrier retaining ring is removed.

Pan and Filter Assembly Removal

1. Remove the transmission oil pan screws (76).
2. Remove the transmission oil pan (75) and the transmission oil pan gasket (73).
3. Remove the transmission oil filter assembly (72).
4. The filter may help in diagnosis. Cut away the top portion of the plastic filter housing and remove. Inspect the filter for the presence of the following items which may indicate wear or corrosion: Clutch material Bronze slivers indicating bushing wear Steel particles
5. Remove the oil filter seal (71).

Secondary Fluid Pump Assembly Removal (M33 Model Only)

1. Disconnect the electrical connector from the secondary fluid pump (108).
2. Remove retaining bolts (109 and 110) from the secondary fluid pump (108).
3. Remove the secondary fluid pump (108).

Valve Body and Wiring Harness Removal

1. Remove all electrical connectors (1-6) from the electrical components.
2. Remove the torque converter clutch (TCC/PWM) pulse width modulation retainer clip (395).
3. Remove the TCC/PWM solenoid (396).
4. Remove the TCC solenoid bolts (68).
5. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so that it hangs over the side of the transmission.
6. Remove the transmission fluid pressure (TFP) manual valve position switch assembly bolts (62, 70).
7. Remove the TFP manual valve position switch (69).
8. Remove the manual detent spring bolt (64).
9. Remove the manual detent spring assembly (63).
10. Remove all valve body bolts (62).
11. Remove the fluid level indicator stop bracket (93) - model dependent.
12. Lift the valve body carefully so that the checkballs remain on the spacer plate in the correct location. While lifting the valve body, disconnect the manual valve link from the manual valve.
13. Remove the 7 valve body checkballs (2-6, 8, 12).
14. Remove the accumulator cover bolts (58, 59 or 117, 118).
15. Remove the 1-2 accumulator cover and pin assembly (57 or 116).
16. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104).
17. Remove the spacer plate support bolts (77).
18. Remove the spacer plate support (53 or 113).
19. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard gaskets. Do not reuse.
20. Remove the 3-4 accumulator spring (model dependent) and the 3-4 accumulator piston.
21. Remove the case checkball (#1).

Scheme 636

Remove the O-ring (618) from the turbine shaft. O-Ring location is model dependent.

Oil Pump Removal

Tools Required

1. J 37789-A Oil Pump Remover/Installer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 39119 Oil Pump Remover/Installer Adapter. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Remove all pump bolts (2).
2. Install J 39119 over stator shaft until it locks under splines.
3. Install J 37789-A .
4. To prevent slipping, securely fasten the J 37789-A around the J 39119 by tightening the bolt (1) with a wrench.
5. Turn the T-handle on top of J 37789-A .
6. Lift the pump out of the case.
7. Some Models use an external fluid pump seal (5) that can be removed after the pump is removed.
8. Remove the pump cover to case gasket (6).

2-4 Band, Input Clutches, Input Gear Set Removal

1. Remove the band anchor pin.
2. Remove the input housing and shaft assembly and the reverse input clutch housing and drum assembly.
3. Remove the 2-4 band assembly (602).

Reaction Gear Set Removal

1. Use snap ring pliers remove the output shaft to input carrier retainer (661).
2. Remove the input carrier assembly (662) and remove the bearing assembly (663).
3. Remove the input internal gear (664) and the reaction carrier shaft assembly (666).
4. Remove the thrust washer (669a or 669b) and the reaction sun shell (670).

1. Remove the reaction sun gear (673) and the thrust washer (674).
2. Remove the low and reverse support retainer ring (676).
3. Remove the J 29837-A .
4. Push on the output shaft (687) in order to loosen the low and reverse clutch support (679).
5. Remove the low and reverse clutch support (679).
6. Remove the output shaft (687).
7. Remove the low and reverse clutch support retainer spring (680).
8. Remove the reaction carrier assembly (681).
9. Remove the following components: The low and reverse clutch fiber plate assembly (682C) The low and reverse clutch steel plates (682D) The low and reverse clutch selective plate (682B) The low and reverse clutch waved plate (682A)
10. Remove the following components: The thrust bearing assembly (reaction carrier support) (683) The internal reaction gear (684) The internal reaction gear support (685) The reaction gear support bearing (692)

Inner Manual Linkage Removal

1. Remove the following parts: Hex head nut (90) Manual valve link (89) Detent lever (88) Parking lock actuator assembly (85) Manual shaft retainer (83) Manual shaft (84)
2. Remove the manual shaft seal (82) with a screwdriver.
3. Remove the following components: The parking lock bracket bolt (87) The parking lock bracket (86)

Low and Reverse Clutch Piston Removal

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 34627 Snap Ring Remover and Installer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 42628 Disc. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Install the J 23327-1 and the J 42628 .
2. Tighten the J 23327-1 .
3. Remove the low and reverse clutch retainer ring (693) using the J 34627 .
4. Remove the low and reverse clutch spring assembly (694).
5. Blow compressed air into the case passage to remove the low and reverse clutch piston (695). (1) LO Feed Passage (2) REV Feed Passage

1. Install the 2-4 servo into the case.
2. Install oil pan with only four bolts to align pan to case.
3. Use the J 29714-A in order to compress the servo cover.
4. Install the servo cover retaining ring.
5. Remove oil pan.
6. Pour solvent into the accumulator bore until the channel is filled. Watch for leaks in the case channel.
7. If leakage from the oval shaped hole is observed, replace the third accumulator retainer and ball assembly.

Third Accumulator Retainer and Ball Replacement

1. Remove the third accumulator retainer and ball assembly, using a 6.3 mm (0.25 in) #4 screw extractor.
2. Scribe a mark at 42 mm (1.653 in) on a 9.5 mm (0.375 in) diameter metal rod. The scribe mark is used to gage the proper depth of the third accumulator retainer and ball assembly.
3. Perform the following functions: Line up the oil feed slots in the third accumulator retainer and ball assembly (40) with the servo bore. Using the 9.5 mm (0.375 in) diameter metal rod, install the third accumulator retainer and ball assembly.
4. Ensure that the third accumulator retainer and ball assembly and the scribe mark on the rod are flush with the case surface.
5. Check the third accumulator retainer and ball assembly (40) for alignment. The slot in the retainer must be completely open in the servo bore.

Tools Required

1. J 8092 Driver Handle
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Remove the case rear oil seal (106) (Y-car Only).
2. Remove the case bushing (7) using J 8092 and J 34196-10 which is part of kit J 34196-B .

Tools Required

1. J 8092 Driver Handle
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 42198 Case Rear Oil Seal Installer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Install a case bushing (7) using J 8092 and J 34196-10 which is part of kit J 34196-B .
2. Install a case rear oil seal (106) (Y-car Only) using J 42198 .

Scheme 637

Install a new manual shaft seal (82).

Low and Reverse Clutch Piston Installation

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 34627 Snap Ring Remover and Installer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 36850 Transjel Lubricant. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Install the transmission (low and reverse clutch outer, center, inner) seals (696) on the low and reverse clutch piston (695).
2. Lubricate the seals with assembly lubricant J 36850 or an equivalent.
3. Install the low and reverse clutch piston (695) into the case. The notch in the piston must be aligned with the parking brake pawl window, in the case.
4. Install the low and reverse clutch spring assembly (694). Using the J 23327-1 , compress the low and reverse clutch spring assembly (694). Using J 36850 install the low and reverse clutch retainer ring (693).

Inner Manual Linkage Installation

1. Install the parking lock bracket (86).
2. Install the parking lock bracket bolt (87). Tighten: Tighten the bolt to 31 N.m (23 lb ft).
3. Inspect the following items: The parking brake pawl (81) for damage or cracks The parking pawl return spring (80) for being broken or missing
4. Inspect the following items: The manual shaft retainer (83) for damage or cracks The manual shaft (84) for damage or burrs The parking lock actuator assembly (85) for damage The inside detent lever (88) for damage or cracks The manual valve link (89) for damage The hex head nut (90) for damage or stripped threads
5. Install the following items: The inside detent lever (88) The parking lock actuator assembly (85) The manual shaft (84) (model dependent) The manual shaft retainer (83) The hex head nut (90) The manual valve link (89) Tighten: Tighten the nut to 31 N.m (23 lb ft).

1. Install the reaction carrier/support thrust bearing assembly (683) into the internal reaction gear support (685).
2. Install the reaction gear support to case bearing (692) onto the internal reaction gear support (685). Retain the bearing using J 36850 or equivalent.
3. Install the internal reaction gear (684) and the internal reaction gear support (685) into the case.
4. Install the reaction carrier assembly (681) into the internal reaction gear.

Low and Reverse Clutch Plates Installation

1. Install the waved plate.
2. Install the correct selective spacer plate (from the selection procedure).
3. Install the five fiber plate assemblies and four steel plates, starting with one fiber plate assembly and alternating with steel.
4. Index the steel plate splines in the case as shown.

Low and Reverse Clutch Support Installation

1. Install the low and reverse roller clutch race (675). Simultaneously, turn and insert the race.
2. Rotate the race in order to verify proper operation. The race should only rotate in one direction.
3. Install the (680) into the case.
4. Install the low and reverse clutch support (679), roller clutch and roller clutch race (675) assembly into the case. Position the hub side down during the installation.
5. Install the low and reverse support retainer ring (676) into the case.

Reaction Sun Gear Installation

Tools Required

1. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 8092 Universal Driver Handle - 3/4 in

1. Inspect the reaction sun gear (673) for the following defects: Nicks Scores Damaged spline or teeth A worn bushing (672) A loose or weak retaining ring (671)
2. If the reaction sun gear bushing (672) needs replacement, use J 34196-1 which is part of kit J 34196-B with J 8092 to remove the reaction sun bushing (672) from the reaction sun gear (673).
3. Using J 34196-1 which is part of kit J 34196-B with J 8092 , install a new reaction sun bushing (672) into the reaction sun gear (673).
4. Install the reaction sun gear (673) into the reaction carrier.
5. Install the thrust washer (674) with the tangs pointing down. Index the tangs of the thrust washer with the splines of the low and reverse roller clutch race.

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 7004-A Universal Remover. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 23907 Slide Hammer with Bearing Adapter. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
4. J 25019-14 Stator Pump Bushing Remover. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
5. J 29369-2 Bushing and Bearing Remover 2-3 in. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
6. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Remove the reaction carrier shaft/internal gear retainer (668) and the reaction carrier shaft (666) from the input internal gear (664).
2. Inspect the reaction carrier shaft (666) and the input internal gear (664) for the following defects: Scoring Cracking Damaged or worn bushings A cracked shaft A damaged spline Damaged gear teeth
3. Using J 29369-2 with J 23907 , remove the reaction carrier shaft front bushing (665).
4. Using J 25019-14 with J 7004-A , remove the reaction carrier shaft rear bushing (667).

1. Using J 34196-3 which is part of kit J 34196-B with J 8092 , install a new reaction carrier shaft front bushing (665).
2. Using J 34196-3 which is part of kit J 34196-B with J 8092 , install a reaction carrier shaft rear bushing (667).

1. Install the reaction sun shell (670) into the reaction sun gear.
2. Depending on model, install either a thrust bearing (669A) or thrust washer (669B) as follows: Install thrust washer (669B), tangs down into the holes in the reaction sun shell. Install the thrust bearing (669A) using J 36850 onto the reaction carrier shaft, tangs up, towards the shaft.
3. Install the input internal gear (664) and reaction carrier shaft (666) assembly into the sun gear shell. Index the reaction carrier shaft spline into the reaction carrier.
4. Install the input carrier to reaction shaft thrust bearing assembly (663).

Tools Required

1. J 8433 Two Jaw Puller. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 21427-A Speedometer Gear Puller Adapter. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 36352 Speed Sensor Rotor Installer Kit. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Inspect the internal transmission speed sensor rotor (699) for cracks or damaged teeth.
2. Inspect all splines on the output shaft (687) for cracks or damaged splines.
3. Remove the output shaft seal (691) and the output shaft sleeve (690) (model dependent) 2WD units only.
4. If the internal speed sensor rotor (699) is damaged, replace it.
5. Using J 8433 with J 21427-01 , remove the internal speed sensor rotor (699) from the output shaft (687).

1. Slip a new internal speed sensor rotor (699) over the output shaft splines.
2. Install the J 36352-4 in the groove on the output shaft (687).
3. Place the J 36352-6 on the output shaft (687). Press on the J 36352-6 until it contacts the J 36352-4 in the window (the J 36352-4 will be a positive stop for the J 36352-6 ).

1. Install the output shaft (687).
2. Install the J 29837-A .

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

Scheme 638

Using J 34196-5 which is part of kit J 34196-B with J 8092 , remove the input sun gear front bushing (657) and rear bushing (659).

1. Using J 34196-4 which is part of kit J 34196-B with J 8092 , install the input sun gear front bushing (657).
2. Using J 34196-6 which is part of kit J 34196-B with J 8092 , install the input sun gear rear bushing (659).

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 23456 Booster and Clutch Pack Compressor. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Remove the reverse input clutch housing and drum assembly (605) from the input clutch assembly (621).
2. Remove the stator shaft/selective washer bearing assembly (615).
3. Remove the selective thrust washer (616).
4. Remove the 3rd and 4th clutch backing plate retainer ring (656).
5. Remove all 3rd and 4th clutch plates (653-655).
6. Remove the 3-4 clutch boost spring assemblies (600).
7. Remove the forward clutch backing plate retainer ring (651).
8. Remove the forward clutch selective backing plate (650).
9. Remove the forward clutch sprag assembly.
10. Remove all forward clutch plates (646, 648, 649A, 649B).
11. Remove the input sun gear bearing assembly (637).
12. Remove the input housing to output shaft seal (636).
13. Remove all overrun clutch plates (645A, 645B).
14. Install the J 23327-1 and the J 25018-A .
15. Compress the overrun clutch spring, using the J 23456 .
16. Remove the overrun clutch spring retainer snap ring (635).
17. Remove the J 23327-1 and the J 25018-A .
18. Remove the overrun clutch spring assembly (634).
19. Remove the overrun clutch piston (632).
20. Remove the forward clutch piston (630).
21. Remove the forward clutch housing (628).
22. Remove the 3rd and 4th clutch spring assembly (626).
23. Remove the 3rd and 4th clutch apply ring (625).
24. Remove the 3rd and 4th clutch piston (623).

Overrun Clutch Installation

1. Inspect the fiber plate assemblies (645B) and the steel plates (645A) for the following defects: Damaged tangs Delamination Excessive wear Wear or heat damage
2. Install the overrun clutch plates into the input housing starting with a steel plate (645B) and alternating with fiber plate assemblies (645A).
3. Index the plates in the input housing with the wide notches remaining open.
4. Install the input sun gear bearing assembly (637) into the input housing.

Turbine Shaft Seals Installation

Tools Required

1. J 36418-1B Turbine Shaft Seal Installer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 36418-2A Turbine Shaft Seal Sizer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Use the J 36418-1B in order to install the four turbine shaft oil seal rings (619).
2. Place the J 36418-2A over the turbine shaft oil seal rings (619). Leave the J 36418-2A on the shaft until the reverse input clutch must be installed on the input clutch.

Tools Required

1. J 25019 Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
3. J 7004-A Universal Remover. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
4. J 8092 Universal Driver Handle - 3/4 in - 10

1. Inspect the reverse input clutch housing and drum assembly for the following conditions: Damaged or worn bushings Surface finish on the hub and outer housing - check band surface for flatness Leak at the weld Heat distortion Rolled or distorted retaining ring groove
2. Using the J 25019-16 with the J 7004-A , remove the reverse input clutch front bushing (603).
3. Using the J 25019-4 with the J 8092 , remove the reverse input clutch rear bushing (606).

1. Using the J 25019-9 with the J 8092 , install a reverse input clutch front bushing (603).
2. Using the J 34196-3 which is part of kit J 34196-B with the J 8092 , install a reverse input clutch rear bushing (606).

Reverse Input and Input Clutches Installation

1. Install the selective thrust washer (616) on the input housing (621).
2. Install the stator shaft/selective washer bearing assembly (615) on the input housing (621). The black race on the bearing goes toward the oil pump.
3. Install the reverse input clutch assembly (605) on the input housing (621).
4. Index the reverse input clutch plates with the input clutch hub. Make certain all clutch plates are fully engaged.
5. Install the reverse input and the input clutch assembly into the transmission case.
6. Index the 3rd and 4th clutch plates with the input internal gear. Ensure that all clutch plates are fully engaged. When properly assembled, the reverse input clutch housing will be located just below the case oil pump face.

2-4 Band Assembly Installation

1. Inspect the 2-4 band assembly (602) for damage or wear.
2. Install the 2-4 band (602) into the case.
3. Install the band anchor pin into the case.
4. Index the band to fit the band anchor pin into the band.

Tools Required

1. J 41778-1 Pump Body Bushing Installer/Remover. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 41778-2 Pump Body Bushing Position Stop. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Inspect the oil pump body for the following defects: Worn or damaged bushings Foreign material or debris Porosity Scored or irregular mating faces Cross channel leaks Ring groove damage
2. Remove the front helix retainer (244).
3. Remove the oil seal assembly (243).
4. Using the J 41778-1 with an arbor press, remove the pump body bushing (242).
5. Using J 41778-1 with an arbor press, install a new pump body bushing (242).
6. Use the J 41778-2 to ensure proper bushing depth.

Tools Required

1. J 7004-A Universal Remover. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 8092 Universal Driver Handle - 3/4 in - 10
3. J 21465-01 Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
4. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Inspect the pump cover, all check valve retainer and ball assemblies (237), cup plugs (235, 236) and orificed cup plugs (238, 240).
2. Inspect the pump cover for the following: Worn or damaged bushings Foreign material or debris Porosity Scored or irregular mating faces Cross channel leaks Ring groove damage
3. Using the J 21465-15 with the J 7004-A , remove the stator shaft front bushing (234).
4. Using the J 25019-14 with the J 7004-A , remove the stator shaft rear bushing (241).

1. Using the J 21465-2 and the J 8092 , install a new stator shaft front bushing (234).
2. Using the J 34196-2 which is part of kit J 34196-B and the J 8092 , install the stator shaft rear bushing (241).

Oil Pump Assembly Installation

Tools Required

1. J 25025-1 Dial Indicator Mounting Post. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 39855 Stator Shaft Seal Installer. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Install the J 25025-1 .
2. Remove the J 39855-2 which is part of kit J 39855 .
3. Install the pump to drum thrust washer (601).
4. Use J 36850 or equivalent to retain the washer to the pump.
5. Install the oil pump o-ring seal into the oil pump o-ring groove - some models.
6. Install the pump cover to case gasket (6).
7. Install the oil pump assembly (4) into the case and align all holes properly.
8. Install the pump to case bolts (2) with new O-ring seals (3). Tighten: Tighten the bolts to 29 N.m (21 lb ft).
9. Remove the J 25025-1 .
10. Install the remaining pump to case bolts (2) and O-ring seals (3), in the holes where the J 25025-1 were. Tighten: Tighten the bolts to 29 N.m (21 lb ft).

1. Install the oil pump seal (5) - some models. Seat oil pump seal (5) by hand, between pump body and case. Ensure the seal is evenly seated.
2. Install the converter housing (102).
3. Install the converter housing bolts (94) to the transmission case. Use the J 41510 . Tighten: Tighten converter housing bolts evenly in a star pattern sequence. Tighten the converter housing bolts (94) to 65-75 N.m (48-55 lb ft).

Turbine Shaft O-Ring Installation

Install the O-ring (618) on the turbine shaft. O-Ring location is location dependent.

1. Install the following items: The isolator valve (398) The regulator apply spring (397) The regulator apply valve (380) The bore plug (381) The bore plug retainer (395)
2. Install the following items: The 4-3 sequence valve spring (382) The 4-3 sequence valve (383) The 3-4 relay valve (384) The bore plug (381) The bore plug retainer (395)
3. Install the following items: The 3-4 shift valve (385) The 3-4 shift valve spring (386) The bore plug (381) The bore plug retainer (395)
4. Install the following items: The reverse abuse valve (387) The reverse abuse valve spring (388) The bore plug (359) The coiled spring pin (360) The 3-2 downshift valve (389) The 3-2 downshift valve spring (390) The bore plug (381) The bore plug retainer (395)
5. Install the following items: The 3-2 control valve spring (392) The 3-2 control valve (391) The 3-2 control solenoid (394) The solenoid retainer (395)
6. Install the following items: The actuator feed limit valve (374) The actuator feed limit valve spring (375) The bore plug (376) The bore plug retainer (395) The pressure control solenoid (377) 1 - Colorado/Canyon 2 - All other models The solenoid retainer (378) NOTE: Refer to Fastener Notice in Cautions and Notices. The solenoid retainer bolt (364) Tighten: Tighten the bolt to 8-14 N.m (6-10 lb ft).
7. Install the following items: The 1-2 accumulator valve spring (370) The 1-2 accumulator valve (371) in the 1-2 accumulator valve sleeve (372) The 1-2 accumulator valve and sleeve assembly The coiled spring pin (360)
8. Install the following items: The 2-3 shift valve (368) The 2-3 shuttle valve (369) The 2-3 shift solenoid valve (367B) The solenoid retainer (395)
9. Install the following items: The 1-2 shift valve spring (365) The 1-2 shift valve (366) The 1-2 shift solenoid valve (367A) The solenoid valve retainer (395)
10. Install the following items: The forward abuse valve (357) The forward abuse valve spring (358) The bore plug (359) The coiled spring pin (360) The low overrun valve (361) The low overrun valve spring (362)
11. Install the following items: The forward accumulator oil seal (353) on the forward accumulator piston (354) The forward accumulator pin (355) The forward accumulator piston (354) The forward accumulator spring (356) The forward accumulator cover (363) The forward accumulator cover bolts (364)
12. Install the (340).

3-4 Accumulator Installation

1. Inspect the 3-4 accumulator piston (44) for the following conditions: Porosity Cracks Scoring Nicks and scratches
2. Install the 3-4 accumulator piston oil seal ring (45) on the 3-4 accumulator piston (44).
3. Install the 3-4 accumulator piston (44) and seal assembly into the bore.
4. Inspect the 3-4 accumulator spring (46) for cracks.
5. Install the 3-4 accumulator spring.

1-2 Accumulator Installation

Tools Required

1. J 25025-5 Guide Pins. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 36850 Transjel Lubricant. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Inspect the valve body spacer plate and the solenoid screens (49, 50) for damage or debris. Replace the solenoid screens (49, 50) if necessary.
2. Install the #1 checkball into the case.
3. Install the J 25025-5 into the case.
4. Place the spacer plate to case gasket (47) (identified by a "C") and the spacer plate to valve body gasket (52) (identified by a "V") on the spacer plate (48). Retain gaskets on the spacer plate with J 36850 or equivalent.
5. Place the spacer and the spacer plate gaskets on the case.
6. Install the spacer plate support plate (53 or 113).
7. Install the spacer plate support bolts (77).
8. Install the accumulator bolt (115), model dependent. Tighten: Tighten the accumulator bolt to 11 N.m (8.11 lb ft).
9. Install the 1-2 accumulator housing assembly (57 or 116).
10. Install the 1-2 accumulator housing bolts (58, 59 or 117, 118). Tighten: Tighten the bolts 58 and 59 to 11 N.m (8 lb ft). Tighten the bolts 117 and 118 to 8-14 N.m (6-10 lb ft).

Control Valve Body Installation

Tools Required

1. J 25025-5 Guide Pins
2. J 36850 Transjel Lubricant

1. Inspect the wiring harness and solenoid assembly for the following conditions: Damage Cracked connectors Exposed wires Loose electrical terminals Damaged wiring loom Worn, missing, or cut pass-through connector O-ring seal.
2. Install the transmission wiring harness pass-through connector into the transmission case. Ensure connector tabs lock into place.
3. Move the harness to one side in order to install the valve body.
4. Install the checkballs (2-6, 8, 12) in the valve body and retain checkballs with J 36850 or an equivalent. Some models do not use a #5 checkball.
5. Install the valve body over the J 25025-5 Guide Pins, and connect the manual valve link to the manual valve.
6. Install two bolts to hold the valve body in place.
7. Remove the J 25025-5 .
8. Install the fluid level indicator stop bracket (93) if equipped and the valve body bolts (62) that are shown only.
9. Finger tighten the bolts.
10. Inspect the Transmission Fluid Pressure (TFP) Manual Valve Position Switch Assembly for the following conditions: Damage Debris Damaged or missing O-rings Cracked connector Loose electrical terminals Poor terminal retention Sediment in switch membrane
11. Install the TFP manual valve position switch (69) and bolts (62, 70).
12. Install the transmission wiring harness on the valve body.
13. Install the TCC solenoid valve and bolts (68). Tighten: Tighten the bolts to 8-14 N.m (6-10 lb ft).
14. Check that all the valve body bolts are in the correct location. Each bolt number refers to a specific bolt size, as indicated by the following list: 1 - M6 x 1.0 x 65.0 2 - M6 x 1.0 x 54.4 3 - M6 x 1.0 x 47.5 4 - M6 x 1.0 x 17.7 5 - M6 x 1.0 x 35.0
15. Tighten the bolts from the center of the valve body working your way out in a spiral pattern to the outside edge. Tighten: Tighten the bolts to 8-14 N.m (6-10 lb ft).
16. Install the TCC PWM solenoid valve (396) and the solenoid retainer (395).
17. Snap the wiring harness in place on the valve body bolts. Ensure the harness loom tab is located under the TFP switch.
18. Install the wiring connectors to the electrical components as indicated by the following list: 1 - Transmission Fluid Pressure (TFP) manual valve position switch 2 - 1-2 Shift Solenoid 3 - 2-3 Shift Solenoid 4 - Pressure Control Solenoid (PCS) 5 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid 6 - 3-2 Shift Solenoid

Manual Detent Spring Installation

1. Inspect the manual detent spring assembly (63) for cracks or damage.
2. Install the manual detent spring assembly (63).
3. Install the manual detent spring bolt (64). Tighten: Tighten the bolt to 20-27 N.m (15-20 lb ft).

1. Install the secondary fluid pump to the valve body.
2. Install the secondary fluid pump bolts (109, 110). Tighten: Tighten the secondary fluid pump bolts to 11-14 N.m (8-10 lb ft).
3. Connect the electrical connector to the secondary fluid oil pump.

Oil Filter Assembly Installation

1. Lubricate the filter seal (71) with transmission fluid.
2. Use a socket the same size diameter as the filter seal (71) and install the seal.
3. Install the transmission oil filter assembly (72).

Secondary Fluid Pump Filter Replacement (M33 Model Only)

1. Remove the secondary fluid pump. Refer to «Secondary Fluid Pump Assembly Removal (M33 Model Only)»(ref-186419-S36757760812005083000000) .
2. Remove the retaining push clip from the secondary fluid pump.
3. Rotate filter upward and separate from the pump.
4. Install a new filter and rotate filter downward.
5. Install a new push clip.
6. Install the secondary fluid pump. Refer to «Secondary Fluid Pump Assembly Installation (M33 Model Only)»(ref-186419-S29063911122005083000000) .

Transmission Oil Pan Installation

1. Place the transmission oil pan gasket (73) on the case.
2. Place the transmission oil pan (75) on the case.
3. Install all of the transmission oil pan screws (76). Tighten: Tighten the screws to 16 N.m (11.8 lb ft).

2-4 Servo Assembly Installation

Tools Required

1. J 22269-01 Accumulator and Servo Piston Remover. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .
2. J 29714-A Servo Cover Depressor. See «Special Tools and Equipment»(ref-186419-S08249321062005083000000) .

1. Inspect the 4th apply piston (25), the 2-4 servo cover (28), the 2nd apply piston (17), and the servo piston inner housing (20) for the following conditions: Cracks Scoring Burrs and nicks
2. Install the following seals: The 4th apply piston outer oil seal ring (26) on the 4th apply piston (25). The 2-4 servo cover O-ring seal (27) on the 2-4 servo cover (28). The 2nd apply piston outer (18) and inner (19) oil seal rings on the 2nd apply piston (17). The O-ring seal (21) on the servo piston inner housing (20).
3. Install the servo cushion outer spring (16), the servo cushion inner spring (105) (model dependent) and the cushion spring retainer (15) in the 2nd apply piston (17).
4. Use the J 22269-01 and compress the second apply piston assembly (17).
5. Install the second apply piston retaining ring (14).
6. Assemble the 2-4 servo components in the order shown: (12-15, 17, 20, 22-25, 28, 29).
7. Install the 2-4 servo assembly into the 2-4 servo bore.
8. Install the J 29714-A .
9. Tighten the bolt on the J 29714-A in order to compress the servo cover.
10. Install the servo cover retaining ring.

Case Extension Bushing Replacement (2WD Truck/Utility/Van Only )

Tools Required

1. J 8092 Driver Handle
2. J 23062-14 Bushing Remover
3. J 34196-B Transmission Bushing Service Set

1. Inspect the case extension for the following conditions: Porosity Cracks Nicks Burrs Worn bushings
2. Remove the case extension oil seal assembly (34) (model dependent).
3. Using the J 23062-14 and the J 8092 , remove the case extension bushing (33).
4. Using the J 34196-4 which is part of kit J 34196-B and the J 8092 , install a case extension bushing (33).

1. Using the J 21426 , install an output shaft sleeve (690) and an output shaft seal (691). Do not push the sleeve past the machined surface on the output shaft.
2. Install the case extension to case seal (30) and the case extension (31).
3. Install the case extension to case bolts (32). Tighten: Tighten the bolts to 45 N.m (33 lb ft).
4. Inspect the transmission speed sensor for the following conditions: Cracks Nicks Damage
5. Install a new O-ring seal (37) on the internal transmission speed sensor (36).
6. Install the internal transmission speed sensor (36).
7. Install the speed sensor retaining bolt (35). Tighten: Tighten the bolt to 12 N.m (9 lb ft).
8. Using the J 21426 , install the case extension oil seal assembly (34) (model dependent).

1. Install the torque converter.
2. Install the J 21366 .