Home ReviewsRefund
Home/Chevrolet/Tracker/Chevrolet Tracker II (1998-2004)/Repair manual/Automatic Trans/Automatic Transmission Servicing: Removal & Installation
Contents Wiring diagrams Section: Automatic Trans All sections

Automatic Transmission Servicing: Removal & Installation Chevrolet Tracker II

Automatic Trans 14 illustrations ~2701 words

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION.

Removal

Remove the fluid level indicator. Raise and suitably support the vehicle. Remove one bolt and the fluid filler tube from the transmission case. Remove the O-ring seal. Inspect the fluid filler tube O-ring for cuts or other damage. Replace as necessary.

Installation

Apply transmission assembly lubricant to the fluid filler tube O-ring. Install the filler tube into the transmission case. Secure the filler tube with one bolt. Tighten the fluid filler tube bracket bolt to specification. See TORQUE SPECIFICATIONS . Lower the vehicle. Install the fluid level indicator. Refill transmission with appropriate fluid to proper level. See LUBRICATION .

  1. Raise and support the vehicle. Remove the 4 front skid plate bolts and the front skid plate.
  2. Place a drain pan or suitable container under the transmission cooler hoses. Remove the 2 screws from the cooler hose retainer clamps (2). (Scheme 14) Remove the cooler hoses from the cooler hose retainer clamps.
  3. Remove the following items from the transmission cooler: 2 inlet hose clamps, transmission cooler hoses and the 2 outlet hose clamps. (Scheme 14)
  4. Remove the following items from the inlet and outlet cooler pipes at the transmission: 2 inlet hose clamps (3), 2 outlet hose clamps (3) and the transmission cooler hoses (1, 2). (Scheme 15)
  1. Install the transmission cooler hoses to the inlet and the outlet cooler pipes at the transmission. Secure the transmission cooler hoses with the 2 inlet and outlet hose clamps (2). (Scheme 15)
  2. Install the transmission cooler hoses to the transmission cooler (1). Secure the transmission cooler hoses with the 2 inlet and outlet hose clamps (2). (Scheme 14)
  3. Install the transmission cooler hoses to the cooler hose retainer clamps. Secure the transmission cooler hoses with the 2 screws.
  4. Install the front skid plate to the vehicle. Secure the front skid plate with the 4 bolts. Tighten the front skid plate bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000). Lower the vehicle. Refill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138344-S31568193142002040800000).

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Raise and support the vehicle. Remove the 4 front skid plate bolts and the front skid plate.
  2. Place a drain pan or suitable container under the transmission cooler hoses. Remove the one bolt (2) and the cooler pipe clamp from the transmission. (Scheme 14)
  3. Remove the inlet and the outlet transmission cooler pipes from the transmission by loosening both of the flare nuts at the cooler pipe fittings. Remove the drain pan from under the vehicle.
  4. Inspect the transmission cooler pipes for kinks or other damage. Replace the cooler pipes as necessary. Inspect the cooler pipe flare nuts for damage. Replace the nuts as necessary.
  1. Install the inlet and the outlet transmission cooler pipes (1) to the transmission by threading both of the flare nuts into the cooler pipe fittings and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  2. Install the cooler pipe clamp (2) to the transmission cooler (1) pipe bracket. (Scheme 14)
  3. Secure the cooler pipe clamp with one bolt. Tighten the cooler pipe clamp bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000). Lower the vehicle. Refill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138344-S31568193142002040800000).
  1. Disconnect the negative battery cable. Put the manual selector in the NEUTRAL position. Remove the 4 screws (1, 6, 3, 4) and the 2 plastic retaining clips (2, 5) from the console. (Scheme 16) Remove the console.
  2. Remove the shift lock solenoid connector (3) from under the carpet. Remove the shift indicator lamp. (Scheme 17)
  3. Remove the 4 bolts from the manual selector from the floor. Raise and support the vehicle.
  4. Remove the following items from the selector lever: The retaining clip, washer and the shift select cable. Remove the select cable lock nut (1). see scheme 7 Remove the shift select cable from the manual shift lever (4). Remove the shift select cable (4) from the vehicle. see scheme 8
  5. Inspect the shift select cable for fraying or kinks. Lower the vehicle. Replace the cable as necessary. Remove the 2 knob screws. Remove the knob. Remove the select indicator assembly. Remove the select lever assembly. (Scheme 17)
  1. Install the select lever assembly. Install the select indicator assembly. Install the knob. Install the 2 knob screws. Place the manual shift lever (3) in the LOW position.
  2. Install the shift select cable (4) into the shift select cable bracket at the transmission. Secure the shift select cable (4). Install the shift select cable into the manual shift lever while moving the manual shift lever back to the Neutral position.
  3. Secure the shift select cable with the select cable lock nut (3). Tighten the shift select cable lock nut to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  4. Lower the vehicle. Make it possible to access both the manual selector and the manual shift lever. Install the shift select cable to the selector lever. Secure the washer with the retaining clip.
  5. Inspect both ends of the shift select cable to ensure that no cable deflection exists. Lower the vehicle. Install the manual selector to the floor. Secure the manual selector to the floor with the 4 bolts. Tighten the manual selector bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  6. Install the shift indicator lamp (1). Install the shift lock solenoid electrical connector (3) under the carpet. Install the console box to the floor. Install the 4 screws (1, 3, 4, 6) and the 2 plastic retaining clips. (Scheme 16) Place the manual selector in the Park position. Connect the negative battery cable. Check for proper operation.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Disconnect the negative battery cable. Raise and support the vehicle. Remove the front propeller shaft. Remove the transmission oil pan. See «DRAINING & REFILLING»(ref-138344-S10551472632002040800000) under LUBRICATION.
  2. Remove the valve body. See «VALVE BODY & ACCUMULATOR PISTONS»(ref-138344-S12612374002002040800000). Remove the 3 fluid pipes in the following order: 6, 7, 4 and 8. see scheme 2
  3. Remove the filter screen and bolts (1). Remove the electrical connector from the shift solenoid assembly.
  4. Remove the following items from the transmission body: 2 bolts, brake apply cover and gasket.
  5. Remove the following components from the lower valve body: 3 bolts, shift solenoid assembly (3) and gasket. (Scheme 18)
  1. Install the new shift solenoid assembly gasket and the shift solenoid assembly (3) to the lower valve body. Secure the shift solenoid assembly onto the lower valve body with the 3 bolts. (Scheme 18) Tighten the shift solenoid assembly bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  2. Install the electrical connector to the TCC solenoid. Install the new brake applying cover gasket to the transmission body. Install the brake apply cover onto the transmission body.
  3. Secure the brake applying cover with the 2 bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000). Apply a thin coat of ATF to the fluid pipe O-rings. Install the filter screen and bolts (1). Install the fluid pipes in the following order: 6, 8, 4 and then 7.
  4. Install the valve body. See «VALVE BODY & ACCUMULATOR PISTONS»(ref-138344-S12612374002002040800000).
  5. Install the new transmission oil pan gasket and oil pan to the transmission. Secure the transmission oil pan to the transmission with the 14 bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  6. Install the transmission drain plug (1) into the transmission and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  7. Install the front propeller shaft. Lower the vehicle. Connect the negative battery cable. Refill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138344-S31568193142002040800000).

Scheme 18

Scheme 18
Scheme 18
  1. Disconnect the negative battery cable. Loosen the Throttle Valve (T.V.) cable lock nut (3) and the adjusting nut. see scheme 9 Remove the T.V. cable from the throttle body linkage. Remove the T.V. cable casing from the T.V. cable bracket (2) at the throttle body.
  2. Raise and suitably support the vehicle. Remove one bolt and the T.V. cable retaining bracket from the transmission. Remove the front propeller shaft. Remove the transmission range switch. See «TRANSMISSION RANGE SWITCH»(ref-138344-S03423515252002040800000).
  3. Remove the transmission oil pan. See «DRAINING & REFILLING»(ref-138344-S10551472632002040800000) under LUBRICATION.
  4. Remove the valve body from the transmission. See «VALVE BODY & ACCUMULATOR PISTONS»(ref-138344-S12612374002002040800000).
  5. Remove the T.V. cable case from the transmission. Inspect the T.V. cable for fraying or kinks. Replace the cable as necessary. Inspect the T.V. cable O-ring for damage. Replace the O-ring if necessary.
  1. Attach the T.V. cable to the transmission. Attach the T.V. cable to the T.V. cable cam while installing the valve body. Install the valve body in the transmission. See «VALVE BODY & ACCUMULATOR PISTONS»(ref-138344-S12612374002002040800000).
  2. Install the transmission range switch. See «TRANSMISSION RANGE SWITCH»(ref-138344-S03423515252002040800000). Install the transmission oil pan and gasket to the transmission. See «DRAINING & REFILLING»(ref-138344-S10551472632002040800000) under LUBRICATION.
  3. Attach the pinion flange yoke (2) to the front differential pinion flange (3) aligning the index (reference marks) (1) on the pinion flange. Secure the pinion flange yoke (2) with 4 bolts and nuts. (Scheme 19) Tighten the propeller shaft bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  4. Lower the vehicle. Position the cable (1) in a 3.94" (100 mm) radius (a) as shown. (Scheme 20) Pull the inner cable (3) with the force of 0.45 ft. lbs. (2 N.m) to remove the slack in the cable. Crimp the stopper (2) to the inner cable (3) 0.03-0.06" (0.8-1.5 mm) from the end of the cable casing as shown in dimension (C).
  5. Install the T.V. cable casing into the T.V. cable bracket at the throttle body. Install the T.V. cable to the throttle body linkage. Connect the negative battery cable. Adjust the T.V. cable. See «THROTTLE VALVE CABLE»(ref-138344-S01931792462002040900000) under ADJUSTMENTS.

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20
  1. Disconnect the negative battery cable. Raise and support the vehicle. Remove the front propeller shaft. Remove the transmission oil pan. See «DRAINING & REFILLING»(ref-138344-S10551472632002040800000) under LUBRICATION.
  2. Remove the valve body. See «VALVE BODY & ACCUMULATOR PISTONS»(ref-138344-S12612374002002040800000). Remove the 3 fluid pipes in the following order: 7, 4 and 8. see scheme 2
  3. Remove the electrical connector from the Torque Converter Clutch (TCC) solenoid. Remove the 2 bolts from the lower valve body. Remove the TCC solenoid (1) from the lower valve body. (Scheme 21)
  4. Inspect the TCC solenoid pipe O-ring for cuts and other damage. Replace the O-ring as necessary.
  1. Install the new TCC solenoid gasket and TCC Solenoid (1) onto the lower valve body. Secure the TCC solenoid onto the lower valve body with the 2 bolts. Tighten the TCC solenoid bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000) .
  2. Install the electrical connector to the TCC solenoid. Apply a thin coat of ATF to the fluid pipe O-rings. Install the fluid pipes in the following order: 8, 4 and 7. Install the valve body. See «VALVE BODY & ACCUMULATOR PISTONS»(ref-138344-S12612374002002040800000) .
  3. Install the drain pan. Install the front propeller shaft. Lower the vehicle. Connect the negative battery cable. Refill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138344-S31568193142002040800000) .
  4. Apply the parking brake and block the vehicle wheels. With the selector lever in the PARK position, start the engine. DO NOT race the engine. Run the engine at idle and move the selector lever through each range and return to the PARK position. With the engine running at idle, remove the fluid level indicator from the filler tube and wipe the indicator off.
  5. Reinsert the fluid level indicator into the filler tube making sure it is seated in its original position. Remove the indicator and check the fluid level. The level should be between the FULL HOT and LOW HOT marks.
  6. If the level is below the LOW HOT mark, add fluid to bring the level to the FULL HOT mark. Bringing the fluid level from the LOW HOT mark to the FULL HOT mark requires 0.3 qts. (.3L) of fluid. Conduct a road test and recheck the transmission level. See «CHECKING FLUID LEVEL & CONDITION»(ref-138344-S14269755672002040800000) under LUBRICATION.

Scheme 21

Scheme 21
Scheme 21
  1. Disconnect the negative battery cable. Remove the cooler lines. Remove one electrical connector from the TR switch (1). (Scheme 22)
  2. Remove the following components from the manual shaft: one nut, one washer and the manual lever with cable attached.
  3. Unstake the lock plate behind the manual shaft nut. Remove the manual shaft nut and the lock plate from the TR switch. Remove one bolt and the TR switch from the manual shaft.
  1. Attach the lock washer and the set nut. Install the TR switch (1) to the transmission by doing the following steps: Turn the manual shaft rearward, turn the manual shaft back 2 notches and set the manual shaft to the NEUTRAL range.
  2. Attach the TR switch to the transmission. Secure the TR switch with one bolt. DO NOT tighten the bolt fully. (Scheme 22)
  3. Tighten the TR switch set nut to 44 INCH lbs. (5 N.m). Bend the claws of the lock washer over the set nut.
  4. Tighten the TR switch retaining bolt with the neutral reference line (2) and the cut out (3) in the TR switch aligned. (Scheme 22) Tighten the TR switch bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  5. Attach the manual lever to the manual shaft with the cable attached. Secure the manual lever with one washer and one nut. Tighten the manual shaft lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  6. Attach the negative battery cable. Apply the parking brake and block the vehicle wheels. Turn the ignition switch to START with the manual selector lever in the PARK position.
  7. Verify that the starter motor operates. Stop the engine. Place the ignition switch in the ON position. Move the gearshift lever from the PARK to the NEUTRAL position.
  8. Turn the ignition switch to the START position. Verify that the starter motor operates. Verify that the starter motor does not operate in the DRIVE, DRIVE 2, LOW, or REVERSE positions.

Scheme 22

Scheme 22
Scheme 22
  1. Remove the fluid level indicator. Disconnect the T.V. cable from the throttle body. Raise and support the vehicle. Remove the front propeller shaft.
  2. Remove the oil pan bolts, oil pan and gasket. See «DRAINING & REFILLING»(ref-138344-S10551472632002040800000) under LUBRICATION. Disconnect the T.V. cable from the T.V. cable cam.
  3. Remove the electrical connectors from the TCC solenoid and the shift solenoid assembly. Remove the one bolt and the solenoid wiring harness.
  4. Remove the valve body filter and gasket. Remove the 14 bolts that attach the valve body to the transmission case.
  5. Apply low compressed air slowly to the fluid passages until the air pressure forces the following items out of the case bores: 2nd brake accumulator. Direct clutch accumulator. Forward clutch accumulator.
  6. Inspect the accumulator pistons for the following: Cracks, scarring or damage.
  7. Inspect the accumulator springs for the following: Weakness, cracks or damage.
  8. Inspect the piston seals for cuts or damage. Inspect the accumulator case bores for scars, nicks or pitting.
CAUTIONTorque sequence and specification is critical to valve body operation. If bolts are tightened at random, valve bores may become distorted and inhibit valve operation. Do not use air powered tools when assembling the valve bodies.
  1. Place the separator plate with the new gasket in the lower valve body. Temporarily install 2 plate bolts at the specified locations (1). (Scheme 23) Install a new upper valve body gasket to the lower valve body. Install the upper valve body gasket and the lower valve body together to the rear upper valve body.
  2. Hand start the 3 lower valve body bolts in the specified locations. (Scheme 24) Turn the lower valve body upside down. Hand start the 4 upper valve body bolts in the specified locations. (Scheme 25)
  3. Remove the 2 temporarily installed bolts. (Scheme 23) Install the lower valve body to the front upper valve body. Hand start the remaining 3 lower valve body bolts.
  4. Turn over the valve body assembly. Hand start the 5 front upper valve body bolts. (Scheme 26) Tighten the upper valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000). Tighten the lower valve body bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  5. Install the following components to the valve body: The manual valve, the detent spring plate and the detent spring bolt. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-138344-S41140421742002040800000).
  6. Install the filter, gasket and oil pan. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-138344-S31568193142002040800000).

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Disconnect the negative battery cable. Raise and support the vehicle. Remove the vehicle speed sensor electrical connector. Remove the one bolt (1) and the vehicle speed sensor (2) from the transmission adapter case. (Scheme 27)

Install the one bolt (1) and the vehicle speed sensor (2) to the transmission adapter case. (Scheme 27) On all models, install the vehicle speed sensor electrical connector. Lower the vehicle. Connect the negative battery cable.

Scheme 27

Scheme 27: Installation
Scheme 27: Installation

More articles — Automatic Transmission Servicing