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Automatic Transmission Servicing: Removal & Installation Chevrolet TrailBlazer I

Automatic Trans 65 illustrations ~5768 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

  1. Raise and support the vehicle.
  2. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION. NOTE: The 1-2 accumulator can be removed without removing the control valve assembly.
  3. Remove the control valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-154782-S17411695032003052300000).
  4. Remove the accumulator cover retaining bolts. (Scheme 16)
  5. Remove the 1-2 accumulator cover assembly.
  6. Disassemble the 1-2 accumulator as follows: Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. (Scheme 17) 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. (Scheme 18)
  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. (Scheme 19)
  11. Remove the spacer plate support retaining bolts. (Scheme 20) NOTE: Use care not to drop the following items that will be removed along with the spacer plate: No. 1 checkball. 3-4 accumulator spring. 3-4 accumulator pin.
  12. Remove the spacer plate support. (Scheme 21)
  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). (Scheme 22)
  15. Inspect the 3-4 accumulator spring for cracks.
  16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. (Scheme 18)
  17. Inspect the 3-4 accumulator piston for the following defects: Porosity. Cracks. Scoring. Nicks and scratches.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Installation

  1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. (Scheme 18)
  2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with assembly lubricant. (Scheme 23)
  3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure the 3-4 accumulator piston legs face away from the transmission case.
  4. Install the alignment pin (2-3) to the transmission case.
  5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate. Use assembly lubricant in order to retain the gaskets to the spacer plate. Gaskets can be identified as follows: The case gasket is identified by a "C". Ensure to place the case gasket on the transmission case side of the spacer plate. The valve body gasket is identified by a "V". Ensure to place the valve body gasket on the valve body side of the spacer plate.
  6. Ensure 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. (Scheme 24)
  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 the spacer plate support retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure the checkball (1) has remained in the proper location. (Scheme 25)
  12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. (Scheme 18)
  13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. (Scheme 17)
  14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure the piston legs face the accumulator cover.
  15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. (Scheme 16) Tighten the accumulator cover retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  16. Remove the alignment pin from the transmission case.
  17. Install the control valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-154782-S17411695032003052300000).
  18. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  19. Lower the vehicle.
  20. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Note. DO NOT remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid.

  1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  2. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY»(ref-154782-S03269032142003052300000).
  3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1). (Scheme 26) 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. Remove the pressure control solenoid. (Scheme 27)
  5. Remove the 1-2 and 2-3 shift solenoid retainers. Remove the 1-2 and 2-3 shift solenoids. (Scheme 28)
  6. Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 28)

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28
  1. Install the 3-2 control solenoid. Install the 3-2 control solenoid retainer. (Scheme 28)
  2. Install the 1-2 and 2-3 shift solenoids. Install the 1-2 and 2-3 shift solenoid retainers.
  3. Install the pressure control solenoid. Ensure the electrical tabs are facing outboard. (Scheme 28)
  4. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  5. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch (1). (Scheme 26) 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. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(ref-154782-S03269032142003052300000).
  7. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  8. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).
  1. Raise and suitably support the vehicle.
  2. Support the transmission with a transmission jack.
  3. Place a drain pan under the vehicle.
  4. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  5. Remove the transmission mount.
  6. Remove the case extension bolts (1).
  7. Remove the case extension (2). (Scheme 29)
  8. Remove and discard the case extension "O" ring seal (3).

Scheme 29

Scheme 29
Scheme 29
  1. Install a new case extension "O" ring seal (3).
  2. Install the case extension (2).
  3. Install the case extension bolts (1). (Scheme 29) Tighten the case extension bolts (1) to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  4. Install the transmission mount.
  5. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  6. Remove the drain pan and the transmission jack.
  7. Lower the vehicle.
  8. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).
  1. Raise and support the vehicle.
  2. Place a drain pan under the vehicle.
  3. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  4. Remove the case extension housing rear oil seal. Use a flat bladed tool and carefully pry the seal from the housing. (Scheme 30)
  5. Inspect the case extension housing for damage. Replace the extension housing if necessary. See «EXTENSION HOUSING ASSEMBLY»(ref-154782-S36523425622003052300000).

Scheme 30

Scheme 30
Scheme 30
  1. Lubricate the inside diameter of the new seal with assembly lubricant.
  2. Use the seal installer with a soft faced mallet to install the seal.
  3. Install the seal to the extension housing. (Scheme 31)
  4. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  5. Remove the drain pan and lower the vehicle.
  6. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).

Scheme 31

Scheme 31
Scheme 31

Raise and support the vehicle. Remove the PNP switch. See PARK/NEUTRAL POSITION SWITCH. Ensure the jackscrew for Selector Shaft Seal Remover (J-43911) is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. (Scheme 32) Rotate the removal tool so the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to ensure the removal tool is firmly attached to the seal shell. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed.

Scheme 32

Scheme 32: Removal
Scheme 32: Removal

Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. (Scheme 33) Position the seal so that it is starting to enter the seal bore. Obtain Selector Shaft Seal Installer (J-43909) and remove the inner sleeve so that the tool will slide over the selector shaft. Slide the selector shaft seal installer into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the selector shaft seal installer and drive the new seal into the seal bore until it is seated at the bottom of the bore. Install the PNP Switch. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See LUBRICATION.

Scheme 33

Scheme 33: Installation
Scheme 33: Installation
  1. Disconnect the transmission cooler lines from the radiator. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  2. Raise the vehicle.
  3. Place a drain pan under the vehicle.
  4. Remove the cooler lines (3 and 4) from the radiator. (Scheme 34)
  5. Separate the front and rear cooler lines at the quick connect fitting (2).
  6. Remove the cooler lines from the retainer (1) located on the radiator shroud.
  7. Remove the front sections of the cooler lines from the vehicle.
  8. Remove the rear sections of the cooler lines from the retainer (1) located on the right side of the engine. (Scheme 35)
  9. Remove the clip (2) that holds the cooler lines together.
  10. Support the transmission with a transmission jack.
  11. Remove the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  12. Remove the front exhaust pipe assembly.
  13. Carefully lower the transmission to gain access to the cooler line fittings.
  14. Disconnect the transmission cooler lines from the transmission. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  15. Disconnect the rear oil cooler lines (2) from the front oil cooler lines (1). (Scheme 36)
  16. Remove the oil cooler lines from the vehicle.

Scheme 34

Scheme 34
Scheme 34

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

Note. Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation.

  1. Install the transmission oil cooler lines to the vehicle.
  2. Install the transmission cooler lines to the transmission. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  3. Connect the rear cooler lines (2) to the front cooler lines (1). (Scheme 36)
  4. Raise the transmission into position.
  5. Install the front exhaust pipe assembly.
  6. Install the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  7. Remove the transmission jack.
  8. Install the clip (2) that holds the cooler lines together. (Scheme 35)
  9. Install the cooler lines to the retainer (1) located on the right side of the engine.
  10. Install the front sections of the cooler lines to the vehicle.
  11. Install the cooler lines to the retainer (1) located on the radiator shroud. (Scheme 34)
  12. Connect the front and rear cooler lines at the quick connect fitting (2).
  13. Install the transmission cooler lines to the radiator. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  14. Remove the drain pan from under the vehicle.
  15. Lower the vehicle.
  16. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).
  1. Disconnect the transmission cooler lines from the radiator. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  2. Raise the vehicle.
  3. Place a drain pan under the vehicle.
  4. Remove the cooler lines (3 and 4) from the radiator. (Scheme 34)
  5. Separate the front and rear cooler lines at the quick connect fitting (2).
  6. Remove the cooler lines from the retainer (1) located on the radiator shroud.
  7. Remove the front sections of the cooler lines from the vehicle.
  8. Remove the rear sections of the cooler lines from the retainer (1) located on the right side of the engine. (Scheme 35)
  9. Remove the clip (2) that holds the cooler lines together.
  10. Support the transmission with a transmission jack.
  11. Remove the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  12. Remove the front exhaust pipe assembly.
  13. Carefully lower the transmission to gain access to the cooler line fittings.
  14. Disconnect the transmission cooler lines from the transmission. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  15. Disconnect the rear oil cooler lines (2) from the front oil cooler lines (1). (Scheme 36)
  16. Remove the oil cooler lines from the vehicle.

Note. Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation.

  1. Install the transmission oil cooler lines to the vehicle.
  2. Install the transmission cooler lines to the transmission. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  3. Connect the rear cooler lines (2) to the front cooler lines (1). (Scheme 36)
  4. Raise the transmission into position.
  5. Install the front exhaust pipe assembly.
  6. Install the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  7. Remove the transmission jack.
  8. Install the clip (2) that holds the cooler lines together. (Scheme 35)
  9. Install the cooler lines to the retainer (1) located on the right side of the engine.
  10. Install the front sections of the cooler lines to the vehicle.
  11. Install the cooler lines to the retainer (1) located on the radiator shroud. (Scheme 34)
  12. Connect the front and rear cooler lines at the quick connect fitting (2).
  13. Install the transmission cooler lines to the radiator. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  14. Remove the drain pan from under the vehicle.
  15. Lower the vehicle.
  16. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).
  1. Disconnect the transmission cooler lines from the radiator. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  2. Remove the rear sections of the cooler lines from the retainer (2) located on the right side of the engine. (Scheme 37)
  3. Remove the clip that holds the cooler lines together.
  4. Support the transmission with a transmission jack.
  5. Remove the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  6. Remove the front exhaust pipe assembly.
  7. Carefully lower the transmission to gain access to the cooler line fittings.
  8. Place a drain pan under the vehicle.
  9. Disconnect the transmission cooler lines from the transmission. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  10. Disconnect the rear oil cooler lines (2) from the front oil cooler lines (1). (Scheme 36)
  11. Remove the oil cooler lines from the vehicle.

Scheme 37

Scheme 37
Scheme 37
  1. Install the transmission oil cooler lines to the vehicle.
  2. Install the transmission cooler lines to the transmission. See «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  3. Connect the rear cooler lines (2) to the front cooler lines (1). (Scheme 36)
  4. Install the cooling line ends (3) to the transmission. (Scheme 37)and «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  5. Raise the transmission into position.
  6. Install the front exhaust pipe assembly.
  7. Install the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  8. Remove the transmission jack.
  9. Install the clip that holds the cooler lines together.
  10. Install the cooler lines to the retainer (2) located on the right side of the engine.
  11. Install the front sections of the cooler lines to the vehicle.
  12. Install the cooler lines to the retainer located on the radiator shroud.
  13. Connect the front and rear cooler lines at the quick connect fitting.
  14. Install the cooler lines (4 and 5) to the radiator. (Scheme 38)and «OIL COOLER LINES QUICK CONNECT FITTINGS»(ref-154782-S36761152102003052800000).
  15. Remove the drain pan from under the vehicle.
  16. Lower the vehicle.
  17. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).

Scheme 38

Scheme 38
Scheme 38

Note. The front and rear sections of the cooler lines can be serviced separately. Refer to the appropriate steps when servicing individual lines. Perform the following procedure when removing the cooler lines from the quick connect fittings.

  1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 2" (5 cm).
  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. (Scheme 39)
  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. (Scheme 40)

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Note. DO NOT reuse any of the existing fittings if there is excessive corrosion. DO NOT reuse any of the existing retaining rings that were removed from the existing quick connect fittings. All retaining rings being installed must be new. Ensure the following procedures are performed when installing the new retaining rings onto the fittings.

  1. Install a new retaining ring (E-clip) into the quick connect fitting using the following procedure: Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 41) Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. (Scheme 42) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 43) Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. (Scheme 44) Install the new retaining ring (E-clip) into the remaining quick connect fittings.
  2. Install the cooler lines into the quick connect fitting. (Scheme 45)
  3. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
  4. DO NOT use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 46)
  5. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
  6. 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. (Scheme 47)
  7. Ensure that the plastic cap is fully seated against the fitting.
  8. Ensure that no gap is present between the cap and the fitting. (Scheme 48)
  9. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. (Scheme 47)
  10. A hidden yellow identification band indicates proper joint seating. (Scheme 49)
  11. Inspect the transmission fluid level.

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49
  1. Apply the parking brake.
  2. Shift the transmission into Neutral.
  3. Raise and support the vehicle.
  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 PNP switch to the transmission.
  8. Remove the PNP switch from the manual shaft. (Scheme 50) If the PNP switch did not slide off the manual shaft, file the outer edge of the manual shaft to remove any burrs.

Scheme 50

Scheme 50
Scheme 50

Note. If a new switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in it proper position for installation and the use of neutral position adjustment tool will not be necessary.

  1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. (Scheme 50)
  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 alignment tool onto the PNP switch. (Scheme 51) Ensure 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 the bolts securing the switch to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  6. Remove the alignment tool from the switch. 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 the control lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  9. Lower the vehicle.
  10. Check the switch for proper operation. The engine must start with the transmission in the Park and Neutral positions only. If proper operation of the switch can not be obtained, replace the switch.

Scheme 51

Scheme 51
Scheme 51
  1. Raise and support the vehicle.
  2. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. (Scheme 52)
  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). (Scheme 53)
  6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
  7. Remove the pressure regulator valve (1).

Scheme 52

Scheme 52
Scheme 52

Scheme 53

Scheme 53
Scheme 53
  1. Install the pressure regulator valve (1).
  2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). (Scheme 53)
  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. (Scheme 52)
  7. Install the transmission oil filter and pan. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  8. Lower the vehicle.
  9. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).
  1. Ensure the vehicle is in the Park position.
  2. Raise and support the vehicle.
  3. Remove the end of the range selector cable from the transmission range selector lever ball stud (6). see scheme 9
  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. If the vehicle is equipped with 4WD, remove the cable from the retainers located on the transfer case.
  7. Push the cable grommet (2) up through the floor panel. (Scheme 54)
  8. Lower the vehicle.
  9. Remove the console. See appropriate SHIFT INTERLOCK SYSTEMS article.
  10. Remove the drivers side front mat and carpet.
  11. Remove the end of the range selector cable (1) from the floor control ball stud. (Scheme 55)
  12. Remove the range selector cable (2) from the floor shift control assembly.
  13. Remove the tape and grommet on the shift cable from the floor panel.
  14. Remove the range selector cable (3) from the vehicle.

Scheme 54

Scheme 54
Scheme 54

Scheme 55

Scheme 55
Scheme 55
  1. Push the cable down through the floor panel and install the grommet (2). (Scheme 54)
  2. Install the range selector cable (2) to the floor shift control assembly. (Scheme 55)
  3. Install the end of the range selector cable (1) to floor control ball stud.
  4. Install the drivers side front mat and carpet.
  5. Install the console.
  6. Raise and support the vehicle.
  7. Install the cable to the retainer (3) on the floor panel. see scheme 9 If the vehicle is equipped with 4WD, install the cable to the retainers located on the transfer case.
  8. Install the range selector cable (4) to the bracket (1).
  9. Install the retainer (5) to the range selector cable.
  10. Install the end of the range selector cable to the transmission range selector lever ball stud (6).
  11. Adjust the range selector cable.
  12. Lower the vehicle and check for proper operation.
  1. Raise and support the vehicle.
  2. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 56) Depress both tabs on the connector and pull straight up, DO NOT pry the connector. NOTE: Removal of the valve body is not necessary for the following procedure.
  4. Remove the 1-2 accumulator assembly. DO NOT remove spacer plate. See «ACCUMULATOR ASSEMBLY»(ref-154782-S03269032142003052300000).
  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). (Scheme 26)
  6. Remove the TCC PWM solenoid retainer.
  7. Remove the TCC PWM solenoid to access one of the TCC solenoid retaining bolts. (Scheme 57)
  8. Remove the pressure control solenoid retainer.
  9. Remove the pressure control solenoid. (Scheme 27)
  10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 58)
  11. Using seal protector retainer installer, release the pass-through electrical connector from the transmission case. (Scheme 59) Use the small end of the seal protector retainer installer over the top of the connector. Twist to release the 4 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. (Scheme 60)

Scheme 56

Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57

Scheme 58

Scheme 58
Scheme 58

Scheme 59

Scheme 59
Scheme 59

Scheme 60

Scheme 60
Scheme 60
  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. (Scheme 59)
  3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. (Scheme 58) Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  4. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  5. Install the pressure control solenoid. (Scheme 27) Ensure the electrical tabs are facing outboard.
  6. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  7. Install the TCC PWM solenoid to the control valve body. (Scheme 57)
  8. Install the TCC PWM solenoid retainer.
  9. 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).
  10. Install the 1-2 accumulator. (Scheme 26)
  11. 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. (Scheme 56)
  12. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  13. Lower the vehicle.
  14. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).
  1. Raise and support the vehicle.
  2. Remove the fuel tank shield.
  3. Remove the Evaporative Emission (EVAP) canister from its mounting bracket. DO NOT disconnect the canister lines.
  4. Support the transmission with a transmission jack.
  5. Remove the transmission mount-to-transmission support retaining nuts. (Scheme 61)
  6. Remove the lower transmission support-to-frame mounting bolts. (Scheme 62)
  7. Remove the upper transmission support-to-frame mounting bolts. (Scheme 63)
  8. Remove the transmission support from the frame.

Scheme 61

Scheme 61
Scheme 61

Scheme 62

Scheme 62
Scheme 62

Scheme 63

Scheme 63
Scheme 63
  1. Install the transmission support to the frame.
  2. Install the upper transmission support-to-frame mounting bolts. (Scheme 63) Tighten the upper transmission support-to-frame mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  3. Install the lower transmission support-to-frame mounting bolts. (Scheme 62) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  4. Lower the transmission onto the transmission support.
  5. Install the transmission mount-to-transmission support retaining nuts. (Scheme 61) Tighten the transmission mount-to-transmission support retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  6. Install the EVAP canister.
  7. Install the fuel tank shield.
  8. Lower the vehicle.
  1. Ensure removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission: Torque Converter Clutch Solenoid (1) Pressure Control Solenoid (2) Internal Wiring Harness (3) 2-3 Shift Solenoid (4) 1-2 Shift Solenoid (5) Transmission Fluid Pressure Manual Valve Position Switch (6) 3-2 Shift Solenoid (7) Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid (8) (Scheme 64)
  2. Remove the fluid level indicator.
  3. Raise and support the vehicle.
  4. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  5. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure manual valve position switch (1). 1-2 shift solenoid (2). 2-3 shift solenoid (3). Pressure control solenoid (4). TCC PWM solenoid (5). 3-2 shift solenoid (6).
  6. Remove the fluid indicator stop bracket bolt (2). (Scheme 65)
  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) to access the TCC solenoid retaining bolts. (Scheme 57)
  10. Remove the TCC solenoid retaining bolts. (Scheme 66)
  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. (Scheme 59)
  13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 67)
  14. Remove the transmission fluid pressure switch.
  15. Inspect the transmission fluid pressure switch for damage or debris. (Scheme 68)
  16. Remove the manual detent spring retaining bolt.
  17. Remove the manual detent spring. (Scheme 69)
  18. Inspect the manual detent spring for cracks or damage. NOTE: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages.
  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. (Scheme 70)
  21. If disassembly of the control valve body is necessary, see appropriate OVERHAUL article.

Scheme 64

Scheme 64
Scheme 64

Scheme 65

Scheme 65
Scheme 65

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67

Scheme 68

Scheme 68
Scheme 68

Scheme 69

Scheme 69
Scheme 69

Scheme 70

Scheme 70
Scheme 70
  1. Install the checkballs (1-7) in the valve body. (Scheme 71)
  2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 70)
  3. Verify the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). (Scheme 72)
  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. (Scheme 73) NOTE: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified.
  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. (Scheme 74) 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. (Scheme 69)
  8. Install the transmission fluid pressure switch. (Scheme 67)
  9. Install but DO NOT tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 67)
  10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. (Scheme 74) Tighten the control valve body bolts (in sequence) to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  11. Ensure the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  12. Install the TCC solenoid with a new "O" ring seal to the valve body.
  13. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  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). (Scheme 59) 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). (Scheme 57)
  18. Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 65) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  19. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure manual valve position switch (1). 1-2 shift solenoid (2). 2-3 shift solenoid (3). Pressure control solenoid (4) TCC PWM solenoid (5). 3-2 shift solenoid (6). (Scheme 26)
  20. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154782-S23228125912003052300000) under LUBRICATION.
  21. Lower the vehicle.
  22. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).

Scheme 71

Scheme 71
Scheme 71

Scheme 72

Scheme 72
Scheme 72

Scheme 73

Scheme 73
Scheme 73

Scheme 74

Scheme 74
Scheme 74

Remove the harness connector. Remove the bolt (2). (Scheme 75) Remove the vehicle speed sensor (1). Remove the "O" ring seal (3).

Scheme 75

Scheme 75: Removal
Scheme 75: Removal

Install the "O" ring seal (3) on the vehicle speed sensor (1). Coat the "O" ring seal (3) with a thin film of transmission fluid. Install the vehicle speed sensor (1) into the transmission case. (Scheme 75) Install and tighten the bolt to specification. See TORQUE SPECIFICATIONS. Connect the wiring harness electrical connector to the vehicle speed sensor. Fill transmission with appropriate fluid to proper level. See LUBRICATION.

Note. Tools required: Servo Cover Depressor (J-29714-A).

  1. Raise and support the vehicle.
  2. Support the transmission with a suitable jack.
  3. Remove the transmission support. See «TRANSMISSION SUPPORT»(ref-154782-S20182199392003052800000).
  4. Remove the front exhaust pipe assembly.
  5. Remove the heat shield. (Scheme 76)
  6. Carefully lower the transmission to gain access to the 2-4 servo.
  7. Install the servo cover depressor.
  8. Tighten the bolt on the servo cover depressor to compress the servo cover. (Scheme 77)
  9. Remove the servo cover retaining ring. (Scheme 78)
  10. Remove the servo cover depressor.
  11. Remove the servo cover and "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. (Scheme 79) Cut and remove the "O" ring seal before removing the cover.
  12. Remove the 2-4 servo assembly from the transmission.
  13. Inspect the 4th apply piston, the 2-4 servo cover, 2nd apply piston, and the piston inner housing for cracks, scoring, burrs and nicks. (Scheme 80)

Scheme 76

Scheme 76
Scheme 76

Scheme 77

Scheme 77
Scheme 77

Scheme 78

Scheme 78
Scheme 78

Scheme 79

Scheme 79
Scheme 79

Scheme 80

Scheme 80
Scheme 80
  1. Install the new seals on the pistons and the servo cover.
  2. Install the 2-4 servo assembly into the transmission.
  3. Install the servo cover depressor.
  4. Tighten the bolt on the servo cover depressor to compress the servo cover. (Scheme 77)
  5. Install the servo cover retaining ring.
  6. Remove the servo cover depressor from the oil pan flange.
  7. Install the oil pan bolt. Tighten the oil pan bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  8. Install the heat shield. Install the 2 bolts securing the transmission heat shield to the transmission. Tighten the heat shield bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154782-S37141348322003052300000).
  9. Install the exhaust pipe assembly.
  10. Install the transmission support.
  11. Remove the transmission jack.
  12. Lower the vehicle.
  13. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-154782-S34876037992003052300000).

More articles — Automatic Transmission Servicing