Automatic Transmission - 4L60-E/4L65-E - Introduction, Service & Replacement: Removal & Installation Chevrolet SSR I

Removal Procedure

1. Loosen the set screw.
2. Pull up to remove the knob from the transmission control.

Installation Procedure

1. Install the knob onto the transmission control.
2. Tighten control knob set screw. Tighten: Tighten the control knob set screw to 2.5 N.m (22 lb in).

1. Ensure that the vehicle is in the park position.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Remove the end of the range selector cable from the transmission range selector lever ball stud (6).
4. Remove the retainer (5) from the range selector cable.
5. Remove the range selector cable (4) from the bracket (1).
6. Remove the cable from the retainer (3) on the floor panel. .
7. Push the cable grommet (2) up through the floor panel.
8. Lower the vehicle.
9. Remove the console. Refer to «Console Replacement»(ref-187800-S00149639652005090100000) in Instrument Panel, Gages and Console.
10. Remove the end of the range selector cable (1) from the floor control ball stud.
11. Remove the range selector cable (2) from the floor shift control assembly.
12. Remove the tape and grommet on the shift cable from the floor panel.
13. Remove the range selector cable (3) from the vehicle.

1. Push the cable down through the floor panel and install the grommet (2).
2. Install the range selector cable (2) to the floor shift control assembly.
3. Install the end of the range selector cable (1) to floor control ball stud.
4. Install the console. Refer to «Console Replacement»(ref-187800-S00149639652005090100000) in Instrument Panel, Gages and Console.
5. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
6. Install the cable to the retainer (3) on the floor panel.
7. Install the range selector cable (4) to the bracket (1).
8. Install the retainer (5) to the range selector cable.
9. Install the end of the range selector cable to the transmission range selector lever ball stud (6).
10. Adjust the range selector cable. Refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-187837-S22989549872005090100000) .
11. Lower the vehicle and check for proper operation.

1. Apply the parking brake.
2. Shift the transmission into neutral.
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187837-S27531633042005090100000) .
5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission.
6. Remove the transmission range selector cable bracket from the vehicle.

1. Install the transmission range selector cable bracket to the vehicle.
2. Install the transmission range selector cable bracket bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install the transmission range selector cable to the bracket (2) and the lever. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187837-S27531633042005090100000) .
4. Lower the vehicle.
5. Check the vehicle for proper operation. If adjustment of the cable is necessary, refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-187837-S22989549872005090100000) .

1. Remove the front floor console. Refer to «Console Replacement»(ref-187800-S00149639652005090100000) in Instrument Panel and Console.
2. Disconnect the shift lock control solenoid wiring harness.
3. Remove the end of the range selector cable (1) from the transmission control ball stud.
4. Remove the range selector cable (2) from the floor shift control.
5. Remove the transmission control bolts.
6. Remove the transmission control.

1. Install the transmission control.
2. Install the transmission control bolts. Tighten: Tighten the transmission control bolts to 25 N.m (18 lb ft).
3. Install the range selector cable (2) to the floor shift control.
4. Install the end of the range selector cable (1) to the transmission control ball stud.
5. Connect the shift lock control solenoid wiring harness.
6. Install the front floor console. Refer to «Console Replacement»(ref-187800-S00149639652005090100000) in Instrument Panel, Gages and Console.
7. Check for proper operation of the floor shift control.
8. Adjust the range selector cable if necessary. Refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-187837-S22989549872005090100000) .

1. Apply the parking brake.
2. Shift the transmission into neutral.
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
4. Remove the nut securing the transmission control lever to the manual shaft.
5. Remove the transmission control lever from the manual shaft.
6. Disconnect the electrical connectors from the switch.
7. Remove the bolts securing the park/neutral position switch to the transmission.
8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs.

1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats.
2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission.
3. Install the switch to the transmission with 2 bolts finger tight.
4. Position the tool J 41364-A onto the park/neutral position switch. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . Ensure that the 2 slots on the switch where the manual shaft is inserted are lined up with the lower 2 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 securing the switch to 25 N.m (18 lb ft).
6. Remove the J 41364-A from the switch. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . If installing a new switch, remove the positive assurance bracket at this time.
7. Connect the electrical connectors to the switch.
8. Install the transmission control lever to the manual shaft with the nut. Tighten: Tighten the control lever nut to 25 N.m (18 lb ft).
9. Lower the vehicle.
10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Place a drain pan under the transmission oil pan.
3. Remove the oil pan drain plug, if equipped.
4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket.
5. Remove the oil pan bolts from the front and sides of the pan only.
6. Loosen the rear oil pan bolts approximately 4 turns.
7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain.
8. Remove the remaining oil pan bolts.
9. Remove the oil pan and the gasket.
10. Grasp firmly while pulling down with a twisting motion in order to remove the filter.
11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal.
12. Discard the seal.
13. Inspect the fluid color.
14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: Clutch material Bronze slivers indicating bushing wear Steel particles
15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material.

1. Coat the new filter seal with automatic transmission fluid.
2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket.
3. Install the new filter into the case.
4. Install the oil pan and a new gasket.
5. Install the oil pan bolts. Tighten: Tighten the oil pan to transmission case bolts alternately and evenly to 11 N.m (97 lb in).
6. If previously removed, install the range selector cable bracket and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped.
8. Install the oil pan drain plug, if equipped. Tighten: Tighten the oil pan drain plug to 18 N.m (13 lb ft).
9. Lower the vehicle.
10. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) and «Fluid Capacity Specifications»(ref-187837-S32703506492005090100000) .
11. Check the COLD fluid level reading for initial fill only.
12. Inspect the oil pan gasket for leaks.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Position the drain pan as needed.
3. Disconnect the transmission cooler lines from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187837-S23117359872005090100000) .
4. Remove the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
5. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
6. Lower the transmission to gain access for pipe removal.
7. Disconnect the cooler lines from the retainer (2) located on the right side of the engine.
8. Disconnect the transmission cooler lines from the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187837-S23117359872005090100000) .
9. Remove the oil cooler lines from the vehicle.

1. Connect the transmission cooler lines to the vehicle.
2. Connect the transmission cooler lines to the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187837-S23117359872005090100000) .
3. Connect the cooler lines to the retainer (2), located on the right side of the engine.
4. Install the transmission support. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
5. Install the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
6. Connect the transmission cooler lines to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187837-S23117359872005090100000) .
7. Remove the drain pan from under the vehicle.
8. Lower the vehicle.
9. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Fluid Capacity Specifications»(ref-187837-S32703506492005090100000) .

1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in).
2. 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.
3. Remove the retaining ring from the quick connect fitting.
4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting.

1. Install a new retaining ring into the quick connect fitting using the following procedure
2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting.
3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting.
4. Do not install the new retaining ring onto the fitting by pushing the retaining ring.
5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots.
6. Install the cooler line into the quick connect fitting.
7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting.
9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
10. 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.
11. Ensure that the plastic cap is fully seated against the fitting.
12. Ensure that no gap is present between the cap and the fitting.
13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting.
14. A hidden yellow identification band indicates proper joint seating.
15. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

Tools Required

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

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General information.
2. Support the transmission with a suitable jack.
3. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
4. Remove the front exhaust pipe assembly. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
5. Remove the heat shield.
6. Carefully lower the transmission to gain access to the 2-4 Servo.
7. Install the J 29714-A . See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
8. Tighten the bolt in order to compress the servo cover.
9. Remove the servo cover retaining ring.
10. Remove the J 29714-A . See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
11. Remove the servo cover and the O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover.
12. Remove the 2-4 servo from the transmission.
13. 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

1. Install new seals on the servo pistons and the servo cover.
2. Install the 2-4 servo assembly into the transmission.
3. Install the J 29714-A . See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
4. Tighten the bolt in order to compress the servo cover.
5. Install the servo cover retaining ring.
6. Remove the J 29714-A from the oil pan flange. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
7. Install the oil pan bolt. Tighten: Tighten the oil pan bolt to 11 N.m (97 lb in).
8. Install the heat shield.
9. Install the two bolts securing the transmission heat shield to the transmission. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
10. Install the exhaust pipe assembly. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
11. Install the transmission support. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
12. Remove the transmission jack.
13. Lower the vehicle.
14. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring.
4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4).
6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
7. Remove the pressure regulator valve (1).

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 oil filter and pan. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
8. Lower the vehicle.
9. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Remove the transmission oil level indicator.
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Support the transmission using a suitable jack.
4. Remove the transmission mount nut.
5. Remove the transmission crossmember. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
6. Loosen the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) In Engine Exhaust.
7. Lower the transmission slightly.
8. Remove the indicator tube nut.
9. Remove the oil level indicator tube.
10. Remove the seal from the transmission, if necessary.

1. Install a NEW seal to the indicator tube.
2. Install the oil level indicator tube.
3. Install the indicator tube nut. Tighten: Tighten the nut to 47 N.m (35 lb ft).
4. Install the catalytic converter. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
5. Install the transmission crossmember. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
6. Remove the support from the transmission.
7. Lower the vehicle.
8. Install the transmission oil level indicator.
9. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the two bolts securing the transmission heat shield to the transmission.
3. Remove the transmission heat shield from the transmission.

1. Install the transmission heat shield to the transmission.
2. Install the two bolts securing the transmission heat shield to the transmission. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
3. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the park/neutral position (PNP) switch. Refer to «Park/Neutral Position Switch Replacement»(ref-187837-S04130436132005090100000) .
3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal.
4. 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 be sure that the removal tool is firmly attached to the seal shell.
5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed.

1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. 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. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
4. Install the PNP switch. Refer to «Park/Neutral Position Switch Replacement»(ref-187837-S04130436132005090100000) .
5. Lower the vehicle.
6. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

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. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
4. Remove the oil pan, gasket, and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
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 retaining bolts.
10. Remove the TCC solenoid retaining bolts.
11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body.
12. Reposition the harness to the side of the transmission case.
13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control 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 retaining bolt.
17. Remove the manual detent spring.
18. Inspect the manual detent spring for cracks or damage.
19. Remove the remaining control valve body bolts.
20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link.

1. Install the checkballs (1-7) in the valve body.
2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve.
3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2).
4. 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.
5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control 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)
6. Install the manual detent spring.
7. Install but do not tighten the manual detent spring retaining bolt.
8. Install the transmission fluid pressure switch.
9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body.
10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten: Tighten the control valve body bolts (in sequence) to 11 N.m (97 lb in).
11. Ensure that the manual detent spring is aligned properly with the detent lever. Tighten: Tighten the manual detent spring bolt to 31 N.m (23 lb ft).
12. Install the TCC solenoid with a new O-ring seal to the valve body.
13. Install the TCC solenoid bolts. Tighten: Tighten the TCC solenoid retaining bolts to 11 N.m (97 lb in).
14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit.
15. 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).
16. Install the TCC PWM solenoid (1) to the control valve body.
17. Install the TCC PWM solenoid retainer (2).
18. Install the transmission fluid indicator stop bracket (1) and bolt (2). Tighten: Tighten the transmission fluid indicator stop bracket bolt to 11 N.m (97 lb in).
19. 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)
20. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
21. Lower the vehicle.
22. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Remove the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
2. Remove the 1-2 accumulator if necessary. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187837-S09695457572005090100000) .
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) TCC PWM solenoid (5) 3-2 control solenoid (6)
4. Remove the pressure control solenoid retainer.
5. Remove the pressure control solenoid.
6. Remove the 1-2 and 2-3 shift solenoid retainers.
7. Remove the 1-2 and 2-3 shift solenoids.
8. Remove the 3-2 control solenoid retainer.
9. Remove the 3-2 control solenoid.

1. Install the 3-2 control solenoid.
2. Install the 3-2 control solenoid retainer.
3. Install the 1-2 and 2-3 shift solenoids.
4. Install the 1-2 and 2-3 shift solenoid retainers.
5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard.
6. Install the pressure control solenoid retainer and retaining bolt. Tighten: Tighten the pressure control solenoid retaining bolt to 11 N.m (97 lb in).
7. 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)
8. Install the 1-2 accumulator. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187837-S09695457572005090100000) .
9. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
10. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the transmission oil pan and the filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector.
4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187837-S09695457572005090100000) .
5. 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) TCC PWM solenoid (5) 3-2 control solenoid (6)
6. Remove the TCC PWM solenoid retainer.
7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts.
8. Remove the pressure control solenoid retainer.
9. Remove the pressure control solenoid.
10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness.
11. Using J 28458 , release the pass-through electrical connector from the transmission case. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . Use the small end of the J 28458 over the top of the connector. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . Twist in order to release the four tabs retaining the connector. Pull the harness connector down through the transmission case.
12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case.
13. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage Cracked connectors Exposed wires Loose pins

1. Install the wiring harness and TCC solenoid assembly 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 retaining bolts. Tighten: Tighten the control valve body retaining bolts to 11 N.m (97 lb in). Tighten the TCC solenoid retaining bolts to 11 N.m (97 lb in).
4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard.
5. Install the pressure control solenoid retainer and retaining bolt. Tighten: Tighten the pressure control solenoid retaining 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-187837-S09695457572005090100000) .
10. Connect the transmission harness 20-way connector to the transmission pass-through connector. Align the arrows on each half of the connector and insert straight down.
11. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
12. Lower the vehicle.
13. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Remove the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
3. Remove the control valve body. Refer to «Valve Body and Pressure Switch Replacement»(ref-187837-S21683601162005090100000) .
4. Remove the accumulator cover retaining bolts.
5. Remove the 1-2 accumulator cover assembly.
6. Disassemble the 1-2 accumulator. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. Remove the 1-2 accumulator inner and outer springs.
7. Inspect the 1-2 accumulator inner and outer springs for cracks.
8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston.
9. Inspect the 1-2 accumulator piston for the following defects: Porosity Cracks Scoring Nicks and scratches
10. Inspect the 1-2 accumulator cover for the following defects: Porosity Cracks Scoring Nicks and scratches
11. Remove the spacer plate support retaining bolts.
12. Remove the spacer plate support.
13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket.
14. Remove the 3-4 accumulator piston (2).
15. Inspect the 3-4 accumulator spring for cracks.
16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston.
17. Inspect the 3-4 accumulator piston for the following defects: Porosity Cracks Scoring Nicks and scratches

1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston.
2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850 . See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case.
4. Install the J 25025-B (2, 3) to the transmission case. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the gaskets to the spacer plate. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) . The case gasket is identified by a C. Be sure to place the case gasket on the transmission case side of the spacer plate. The valve body gasket is identified by a V. Be sure to place the valve body gasket on the valve body side of the spacer plate.
6. Ensure that the solenoid screens (1, 2) are in place on the spacer plate.
7. Place the checkball (3) on the spacer plate in the location shown.
8. Place the 3-4 accumulator spring (4) on the spacer plate.
9. Install the spacer plate and related components to the transmission.
10. Install the spacer plate support and the spacer plate support retaining bolts. Tighten: Tighten the spacer plate support retaining bolts to 11 N.m (97 lb in).
11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location.
12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston.
13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover.
14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover.
15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. Tighten: Tighten the accumulator cover retaining bolts to 11 N.m (97 lb in).
16. Remove the J 25025-B from the transmission case. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
17. Install the control valve body. Refer to «Valve Body and Pressure Switch Replacement»(ref-187837-S21683601162005090100000) .
18. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
19. Lower the vehicle.
20. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

Transmission Extension Housing Rear Oil Seal Replacement

Tools Required

1. J 21426 Extension Housing Seal Installer. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
2. J 36850 Transmission Assembly Lubricant

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Place a drain pan under the vehicle.
3. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing.
5. Inspect the case extension housing for damage. Replace the extension housing if necessary. Refer to «Transmission Extension Housing Assembly Replacement»(ref-187837-S41031624622005090100000) .

1. Lubricate the inside diameter of the new seal with J 36850 .
2. Use the J 21426 with a soft faced mallet to install the seal. See «Special Tools and Equipment»(ref-187837-S16803645262005090100000) .
3. Install the seal to the extension housing.
4. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
5. Remove the drain pan and lower the vehicle.
6. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Support the transmission with a transmission jack.
3. Place a drain pan under the vehicle.
4. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
5. Remove the transmission mount. Refer to «Transmission Mount Replacement (5.3L)»(ref-187837-S21984943072005090100000) .
6. Remove the case extension bolts (1).
7. Remove the case extension (2).
8. Remove and discard the case extension O ring seal (3).

1. Install a new case extension O ring seal (3).
2. Install the case extension (2). NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the case extension bolts (1). Tighten: Tighten the case extension bolts (1) to 45 N.m (33 lb ft).
4. Install the transmission mount. Refer to «Transmission Mount Replacement (5.3L)»(ref-187837-S21984943072005090100000) .
5. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
6. Remove the drain pan and the transmission jack.
7. Lower the vehicle.
8. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .

1. Remove the harness connector.
2. Remove the bolt (2).
3. Remove the vehicle speed sensor (1).
4. Remove the O-ring seal (3).

1. Install the O-ring seal (3) on the vehicle speed sensor (1).
2. Coat the O-ring seal (3) with a thin film of transmission fluid.
3. Install the vehicle speed sensor (1) into the transmission case.
4. Install the bolt (2). Tighten: Tighten the bolt to 11 N.m (97 lb in).
5. Connect the wiring harness electrical connector to the vehicle speed sensor.
6. Refill the fluid as required.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
2. Support the transmission with a suitable jack.
3. Remove the nuts securing the transmission mount to the transmission support.
4. Remove the transmission support from the vehicle. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
5. Remove the transmission mount bolts (1, 2).
6. Remove the transmission mount from the vehicle.

1. Install the transmission mount.
2. Install the bolts (1, 2) securing the transmission mount to the transmission. Tighten: Tighten the bolts to 65 N.m (48 lb ft).
3. Install the transmission support to the vehicle. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
4. Remove the transmission jack.
5. Install the nuts securing the transmission mount to the transmission support. Tighten: Tighten the nuts to 46 N.m (35 lb ft).
6. Lower the vehicle.

1. Disconnect the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187824-S17690437682005090100000) in General Information.
3. Drain the transmission fluid if necessary. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187837-S06838359552005090100000) .
4. Remove the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
5. Support the transmission with a jack stand at rear of transmission otherwise there is no clearance to remove catalytic converter with transmission jack under pan.
6. Remove the nuts securing the transmission mount to the transmission support.
7. Remove the transmission support from the vehicle. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
8. Remove the transmission mount from the vehicle. Refer to «Transmission Mount Replacement (5.3L)»(ref-187837-S21984943072005090100000) .
9. Remove the front exhaust pipe assembly. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
10. Install transmission jack under transmission pan and remove jack stand from rear of transmission.
11. Lower the transmission to gain access to the top and sides of the transmission.
12. Remove the range selector cable end from the transmission range selector lever ball stud (6) and the bracket (1). Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187837-S27531633042005090100000) .
13. Remove the transmission heat shield. Refer to «Heat Shield Replacement»(ref-187837-S25365258322005090100000) .
14. Disconnect the transmission vent hose, the park/neutral position switch connectors, and the main electrical connector from the transmission. Refer to «Park/Neutral Position Switch Replacement»(ref-187837-S04130436132005090100000) .
15. Remove the transmission harness from the retainers.
16. Remove the bolt that secures the fuel line bracket to the left side of the transmission.
17. Remove the starter to access torque converter bolts. Refer to «Starter Motor Replacement»(ref-187793-S10226095442005090100000) in Engine Electrical.
18. Mark the flywheel and torque converter orientation for reassembly.
19. Remove the flywheel to torque converter bolts.
20. Disconnect the transmission oil cooler lines from the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-187837-S42419403202005090100000) .
21. Plug the transmission oil cooler line connectors in the transmission case.
22. Install a safety chain around the transmission.
23. Remove the nut that secures the filler tube to the bell housing.
24. Remove the transmission filler tube.
25. Remove the remaining nuts, studs and/or bolts that secure the transmission to the engine.
26. Install the J 21366 onto the transmission bell housing to retain the torque converter.
27. Pull the transmission straight back.
28. Remove the transmission from the vehicle.
29. Flush oil cooler and lines. Refer to «Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096)»(ref-187857-S16098271342005090100000) or «Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A)»(ref-187857-S29454323702005090100000) .

1. Install the J 21366 onto the transmission bell housing to retain the torque converter.
2. Raise the transmission into place and remove the J 21366 from the transmission.
3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter made during removal. The torque converter must be flush onto the flywheel and rotate freely by hand.
4. Install nuts, studs and/or bolts securing the transmission to the engine. Tighten: Tighten the studs and/or bolts to 50 N.m (37 lb ft).
5. Install the fuel line retaining bracket to the transmission.
6. Install the flywheel to torque converter bolts. Tighten: Tighten the bolts to 63 N.m (46 lb ft).
7. Install the starter motor. Refer to «Starter Motor Replacement»(ref-187793-S10226095442005090100000) in Engine Electrical.
8. Remove the safety chain from the transmission.
9. Install the transmission filler tube.
10. Install the filler tube nut. Tighten: Tighten the filler tube nut to 10 N.m (7 lb ft).
11. Install the transmission vent hose (2), fuel lines, and the wiring harness to the transmission.
12. Install the transmission harness to the retainers.
13. Install the heat shield to the transmission. Refer to «Heat Shield Replacement»(ref-187837-S25365258322005090100000) .
14. Install the bolts securing the heat shield to the transmission. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
15. Install the shift cable end to the transmission shift lever ball stud (6) and bracket (1). Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187837-S27531633042005090100000) .
16. Put jack stand under rear of transmission instead of transmission jack.
17. Install the front exhaust pipe assembly. Refer to «Catalytic Converter Replacement»(ref-187854-S26164920542005090100000) in Engine Exhaust.
18. Install transmission jack and remove jack stand from rear of transmission.
19. Install the transmission mount to the vehicle. Refer to «Transmission Mount Replacement (5.3L)»(ref-187837-S21984943072005090100000) .
20. Install the transmission support to the vehicle. Refer to «Transmission Support Replacement»(ref-187823-S11886914312005090100000) in Frame and Underbody.
21. Lower the transmission and remove the transmission jack.
22. Install the nuts securing the transmission mount to the transmission support. Tighten: Tighten the nuts to 46 N.m (35 lb ft).
23. Install the rear propeller shaft. Refer to «Propeller Shaft Replacement»(ref-187850-S27089750152005090100000) in Propeller Shaft.
24. Flush the transmission oil cooler and cooling lines at this time, if necessary. Refer to «Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096)»(ref-187857-S16098271342005090100000) or «Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A)»(ref-187857-S29454323702005090100000) .
25. Connect the transmission oil cooler lines (4) to the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-187837-S42419403202005090100000) .
26. Lower the vehicle.
27. Connect the battery. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(ref-187793-S03719997292005090100000) in Engine Electrical.
28. Fill the transmission to the proper level with DEXRON® III transmission fluid and check for leaks. Refer to «Transmission Fluid Checking Procedure»(ref-187857-S28294990692005090100000) .
29. Road test the vehicle and check for proper operation.