Installation Procedure
- Ensure that the transmission manual shaft lever is in the mechanical park position.
- Align and install the cable to the bracket.
- Install the range selector cable end (2) to the transmission range selector lever ball stud (1).
- Install the cable clip on the transfer case, if equipped.
- Install the retainer that secures the cable to the bracket.
- Install the clips on the cable to the floor panel reinforcement.
- Lower the vehicle.
- Install the cable grommet to the floor panel.
- Install the range selector cable to the support.
- Install the bolt securing the cable support to the brace. Tighten: Tighten the bolt to 10 N.m (89 lb in).
- Install the cable to the steering column bracket.
- Ensure the tangs fully seat (snap) into the steering column bracket.
- Install the cable end to the steering column ball stud.
- Install the retainer securing the cable to the steering column.
- Position the carpet and insulation around the driver's area.
- Install the driver's seat. Refer to «Seat Replacement - Front Bucket»(ref-184147-S37056132362005082200000) in Seats.
- Install the instrument panel knee bolster. Refer to «Knee Bolster Replacement»(ref-184121-S33691865652005082200000) in Instrument Panel, Gages, and Console.
- Test the transmission for proper shift operation.
- If all of the gear positions cannot be achieved, adjust the cable. Refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-184202-S19949077502005082200000) .
Removal Procedure
- Apply the parking brake.
- Shift the transmission into neutral.
- Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Disconnect the transmission range selector cable from the shift lever and the bracket (2). Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-184202-S33838582102005082200000) .
- Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission.
- Remove the transmission range selector cable bracket from the vehicle.
- Install the transmission range selector cable bracket to the vehicle.
- Install the transmission range selector cable bracket bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
- Install the transmission range selector cable to the bracket (2) and the lever. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-184202-S33838582102005082200000) .
- Lower the vehicle.
- Check the vehicle for proper operation. If adjustment of the cable is necessary, refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-184202-S19949077502005082200000) .
Scheme 396
Scheme 397
- Ensure that the steering column shift lever is in the park (P) position.
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Ensure that the transmission manual shaft lever is in the park (P) position.
- Grasp the shift cable shifter end (1) in the left hand and the shift cable transmission end (2) in the right hand.
- Align the outside diameter of the transmission end (2) with the inside diameter of the shifter end (1).
- Push the end of the transmission cable (3) inside the shifter end until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together.
- Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system.
- Pull the white cover (5) on the shifter end (1) back.
- Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3).
- Release the white cover (1).
- Verify the white cover (1) conceals the natural colored lock (2).
- If the white cover (1) does not conceal the natural colored lock (2), the shift cable must be re-adjusted. Refer to cable re-adjustment below.
- Lower the vehicle.
- Test the transmission for proper shift operation.
- If all of the gear positions cannot be achieved, the shift cable must be re-adjusted. Refer to cable re-adjustment below.
Scheme 398
Scheme 399
- Place the steering column shift lever back into the park (P) position.
- Raise the vehicle.
- Ensure that the transmission manual shaft lever is in the park (P) position.
- Pull the white cover (1) back to expose the natural colored lock (2). Under the lock (2), insert a flat bladed screwdriver under the lock ramp located at the top of the lock. The lock will pop up, and the transmission end will move slightly away from the shifter end.
- Push the end of the transmission end (3) inside the shifter end (1) until the blue spring (2) on the transmission end (3) is fully compressed, this will engage the inner wire and lock both wires together.
- Release the transmission end (3) and allow the spring (2) to tension/adjust the cable system.
- Pull the white cover (5) on the shifter end (1) back.
- Push the natural colored lock button (4) down to engage the locking teeth on the transmission end (3).
- Release the white cover (1).
- Verify the white cover (1) conceals the natural colored lock (2).
- Install the transmission fill tube seal.
- Install the fill tube.
- Remove the drain pan from under the transmission.
- Install the fill tube bracket nut.
- Lower the vehicle. NOTE: Refer to Fastener Notice in Cautions and Notices.
- Install the oil level indicator. Tighten: Tighten the nut to 47 N.m (35 lb ft).
- Fill the transmission to the proper level with Dexron® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184198-S16784281982005082200000) .
Scheme 400
Scheme 401
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Disconnect the input speed sensor electrical connector (1).
- Remove the input speed sensor bolt.
- Remove the input speed sensor (1).
- Inspect the input speed sensor (1) for any evidence of damage.
- Lubricate the input speed sensor seal with automatic transmission fluid.
- Install the input speed sensor (1). NOTE: Refer to Fastener Notice in Cautions and Notices.
- Install the input speed sensor bolt. Tighten: Tighten the bolt to 11 N.m (96 lb in).
- Connect the input speed sensor electrical connector (1).
- Lower the vehicle.
| IMPORTANT | This procedure is for 2-wheel drive (2WD) vehicles only. If the vehicle is equipped with 4-wheel drive (4WD), the output speed sensor is located on the transfer case. |
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Disconnect the output speed sensor (2) electrical connector.
- Remove the output speed sensor bolt.
- Remove the output speed sensor (2).
- Inspect the output speed sensor (2) for any evidence of damage.
- Lubricate the output speed sensor seal with automatic transmission fluid.
- Install the output speed sensor (2). NOTE: Refer to Fastener Notice in Cautions and Notices.
- Install the output speed sensor bolt. Tighten: Tighten the bolt to 11 N.m (96 lb in).
- Connect the output speed sensor (2) electrical connector.
- Lower the vehicle.
Scheme 402
- Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
- Remove the park/neutral position (PNP) switch. Refer to «Park/Neutral Position Switch Replacement»(ref-184171-S17218411212005082200000) .
- Remove the manual shaft nut and pin.
- Remove the detent lever and actuator.
- Remove the parking pawl bracket bolts.
- Remove the parking pawl return spring.
- Use the modified screw extractor in order to remove the plug.
- Remove the parking pawl shaft retainer, shaft and pawl.
- Remove the manual shaft.
- Remove the manual shaft seal.
Scheme 403
- Install the pawl shaft.
- Install the parking pawl.
- Install the plug using a 8 mm or (5/16 inch) rod with Loctite® or equivalent.
- Install the retainer.
- Install the pawl return spring.
- Install the detent lever to the actuator.
- Install the actuator over the parking pawl.
- 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.
- Install the parking lock bracket bolts. Tighten: Tighten the bolts to 24 N.m (18 lb ft).
- Install the PNP switch. Refer to «Park/Neutral Position Switch Replacement»(ref-184171-S17218411212005082200000) .
- Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
- Fill the transmission to the proper level with Dexron® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184198-S16784281982005082200000) .
- Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) . CAUTION: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result.
- Remove the valve bore plug retainer ring (1).
- Remove the following parts: The valve bore plug The TCC valve The TCC valve spring
Scheme 404
- Install the following parts: The TCC valve spring The TCC valve The valve bore plug
- Install the valve bore plug retainer ring (1).
- Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
- Install the rear servo to the transmission in the following order: 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 bolts (6) NOTE: Refer to Fastener Notice in Cautions and Notices.
- Tighten the cover bolts (61). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
- Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
Scheme 405
- Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). IMPORTANT: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission.
- Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed.
- Remove the retaining ring from the quick connect fitting.
- Discard the retaining ring.
- Pull the cooler line straight out from the quick connect fitting.
- Install a new retaining ring into the quick connect fitting using the following procedure: IMPORTANT: Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. Ensure the following procedures are performed when installing the new retaining rings onto the fittings.
- Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
- Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
- Do not install the new retaining ring onto the fitting by pushing the retaining ring.
- Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
- 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.
- Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting.
- Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
- Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting.
- Ensure that the plastic cap is fully seated against the fitting.
- Ensure that no gap is present between the cap and the fitting.
- Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
- A hidden yellow identification band indicates proper joint seating.
- Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184197-S28503790432005082200000) .
Scheme 406
- Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
- Remove the forward servo cover bolts, cover, and gasket.
- Remove the following parts: Forward servo piston pin (5) O-ring seal (4) Servo piston (3) Retainer (2) Piston spring (1)
- Install the following parts: Piston spring (1) Retainer (2) Servo piston (3) O-ring seal (4) Forward servo piston pin (5) NOTE: Refer to Fastener Notice in Cautions and Notices.
- Install the forward servo gasket, cover, and bolts. Tighten: Tighten the bolts to 24 N.m (18 lb ft).
- Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
Scheme 407
Scheme 408
Scheme 409
- Remove the grille assembly. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) in Exterior Trim.
- Remove the transmission fluid cooler hose from the Auxiliary oil cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000)
- Remove the transmission fluid cooler hose from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000)
- Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-184179-S32392415342005082200000) in Frame and Underbody.
- Remove the transmission fluid cooler hoses from the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000)
- Remove the transmission fluid cooler hoses from the retainer on the engine.
- Remove the transmission fluid cooler hoses from the vehicle.
- Install the transmission fluid cooler hoses to the vehicle.
- Install the transmission fluid cooler hoses to the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000)
- Install the transmission fluid cooler hoses to the retainer on the engine.
- Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-184179-S32392415342005082200000) in Frame and Underbody.
- Lower the vehicle.
- Install the transmission fluid cooler hose to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000)
- Install the transmission fluid cooler hose to the Auxiliary oil cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000)
- Install the grille assembly. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) in Exterior Trim.
Scheme 410
- Remove the grille assembly. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) in Exterior Trim.
- Remove the transmission fluid cooler hoses from the auxiliary cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) .
- Remove the auxiliary oil cooler bolts (1).
- Remove the auxiliary oil cooler push pins (2)
- Remove the auxiliary oil cooler from the vehicle.
- Install the auxiliary oil cooler to the vehicle.
- Install the bolts (1) to the radiator brace. Tighten: Tighten the bolts to 12 N.m (106 lb in).
- Install the push pins (2) to the radiator brace.
- Connect the transmission oil cooler lines to the auxiliary cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-184202-S22465144962005082200000) .
- Install the grille assembly. Refer to «Grille Replacement (GMC)»(ref-184169-S17598306392005082200000) or «Grille Replacement (Chevrolet)»(ref-184169-S35473267962005082200000) in Exterior Trim.
Scheme 411
- Remove the vent hose clip.
- Remove the vent hose from the transmission vent.
- Install the vent hose to the transmission.
- Install the vent hose to the clip.
- Install the bolt and the clamp. Tighten: Tighten the bolt to 10 N.m (89 lb in).
Valve Body and Pressure Switch Replacement
Tools Required
- J 25025-5 Valve Body Align Pin. See «Special Tools and Equipment»(ref-184171-S36905276322005082200000) .
- J 36850 Transjel®
Scheme 412
Scheme 413
Scheme 414
- Ensure that removal of the valve body is necessary before proceeding. IMPORTANT: The following components can be serviced without removing the valve body: The 2-3 solenoid (1) The internal wiring harness (2) The 1-2 shift solenoid (3) The transmission fluid temperature sensor (4) The transmission fluid pressure manual valve position switch (5) The pressure control solenoid (6) The torque converter clutch pulse width modulation (TCC PWM) solenoid (7)
- Remove the fluid level indicator.
- Remove the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
- Disconnect the internal wire harness from the transmission fluid pressure (TFP) manual valve position switch. IMPORTANT: Use care not to loose the 5 O-rings that are located between the TFP manual valve position switch and the valve body.
- Remove the valve body bolts (1) that retain the (TFP) manual valve position switch (2).
- Remove the TFP manual valve position switch.
- Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components.
- Remove the lube oil pipe bolt (6) and retainer (7).
- Remove the lube oil pipe (5).
- Remove the manual shaft detent spring bolt and spring (3). IMPORTANT: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the valve body passages.
- Remove the remaining valve body bolts.
- Carefully lower the valve body from the transmission. Use care not to drop the manual shaft valve.
- Remove the valve body (2) which includes the following: The accumulator housing (1) The valve body to the spacer plate gasket The spacer plate
- Remove the manual valve (1) from the valve body.
- Inspect the manual valve for nicks and burrs.
- Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate.
- Remove the PWM screen (1) from the case passage.
- Remove the manual 2-1 band servo (1).
- Remove the servo piston cushion spring (2).
- Remove the manual 2-1 band servo piston pin retainer ring (4).
- Remove the manual 2-1 band servo piston pin (1).
- Remove the manual 2-1 band servo piston seal (2).
- Remove the 8 checkballs (9 for some models).
Scheme 415
Scheme 416
- Install the 8 checkballs (9 for some models) into the transmission case passages. The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only To hold the checkballs in place, use the J 36850 .
- Install the PWM screen into the valve body.
- Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3).
- Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3).
- Install the manual 2-1 band servo piston pin retainer ring (4).
- Install the manual 2-1 band servo piston cushion spring (2).
- Install the manual 2-1 band servo piston (1).
- Install the manual valve (1) into the valve body.
- To aid in alignment and assembly, install J 25025-5 .
- Install the valve body gasket (6).
- Install the valve body (5). Attach the manual valve to the detent lever while installing the valve body.
- Install the transmission fluid pressure manual valve position switch (2).
- Install the transmission fluid pressure manual valve position switch bolts (1) finger tight.
- Tighten the bolts in the order shown. Tighten: Tighten the bolts to 11 N.m (97 lb in).
- Remove J 25025-5 .
- Install the manual shaft detent roller and spring (3) and bolts.
- 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 valve body.
- Install the lube oil pipe retainer (7) and the bolt (6).
- Install the valve body bolts and tighten in the order shown. Tighten: Tighten the bolts to 11 N.m (97 lb in).
- Install the remaining valve body bolts. Tighten: Tighten the bolts to 11 N.m (97 lb in).
- Connect the internal wiring harness to the valve body electrical components.
- Install the transmission filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-184171-S26501914032005082200000) .
Transmission Extension Housing Rear Oil Seal Replacement
Tools Required
- J 41505 Output Shaft Seal Installer. See «Special Tools and Equipment»(ref-184171-S36905276322005082200000) .
- J 6125-1B Slide Hammer
- J 23129 Universal Seal Remover
- J 36850 Transmission Assembly Lubricant. See «Special Tools and Equipment»(ref-184171-S36905276322005082200000) .
Scheme 417
- Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Place a drain pan under the vehicle.
- Remove the propeller shaft. Refer to «Propeller Shaft Replacement - One Piece»(ref-184221-S28715217102005082200000) or «Propeller Shaft Replacement - Two Piece»(ref-184221-S22027825012005082200000) in Propeller Shaft.
- Using the J 6125-1B (1) and the J 23129 (2), remove the output shaft seal (3) from the extension housing (4).
- Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to «Transmission Extension Housing Assembly Replacement»(ref-184171-S08039727562005082200000) .
Scheme 418
- Lubricate the inside diameter of the new seal with J 36850 .
- Use the J 41505 (1) with a soft faced mallet to install the seal (2).
- Install the seal (2) to the extension housing (3).
- Install the propeller shaft. Refer to «Propeller Shaft Replacement - One Piece»(ref-184221-S28715217102005082200000) or «Propeller Shaft Replacement - Two Piece»(ref-184221-S22027825012005082200000) in Propeller Shaft.
- Remove the drain pan and lower the vehicle.
- Fill the transmission to the proper level with Dexron® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184198-S16784281982005082200000) .
Scheme 419
- Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Support the transmission with a transmission jack.
- Place a drain pan under the vehicle.
- Remove the propeller shaft. Refer to «Propeller Shaft Replacement - One Piece»(ref-184221-S28715217102005082200000) or «Propeller Shaft Replacement - Two Piece»(ref-184221-S22027825012005082200000) in Propeller Shaft.
- Remove the transmission support and the transmission mount. Refer to «Transmission Mount Replacement»(ref-184202-S03129421422005082200000) .
- Remove the case extension bolts (3).
- Remove the case extension (1).
- Remove and discard the case extension O ring seal (2).
- Install a new case extension O ring seal (2).
- Install the case extension (1). NOTE: Refer to Fastener Notice in Cautions and Notices.
- Install the case extension bolts (3). Tighten: Tighten the bolts (3) to 34 N.m (25 lb ft).
- Install the transmission support and the transmission mount. Refer to «Transmission Mount Replacement»(ref-184202-S03129421422005082200000) .
- Install the propeller shaft. Refer to «Propeller Shaft Replacement - One Piece»(ref-184221-S28715217102005082200000) or «Propeller Shaft Replacement - Two Piece»(ref-184221-S22027825012005082200000) in Propeller Shaft.
- Remove the drain pan and the transmission jack.
- Lower the vehicle.
- Fill the transmission to the proper level with Dexron® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-184198-S16784281982005082200000) .
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-184175-S17163319502005082200000) in General Information.
- Support the transmission with a transmission jack.
- Remove the transmission mount to the transmission support retaining nut or nuts.
- Raise the transmission to take the weight off of the mount.
- Remove the transmission mount to the transmission or transfer case adapter mounting bolts (1).
- Raise the transmission just enough to remove the transmission mount.
- Remove the transmission mount from the vehicle.
- Install the transmission mount to the vehicle.
- Install the transmission mount to the transmission or transfer case adapter mounting bolts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
- Lower the transmission.
- Install the transmission mount to the transmission support retaining nut or nuts. Tighten: Tighten the nut or nuts to 40 N.m (30 lb ft).
- Remove the transmission jack.
- Lower the vehicle.