Automatic Transaxle - 4T65-E - Introduction (2 of 2): Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).
2. Use a flat-bladed tool in order to remove the retaining clip (2) from the automatic transaxle range selector cable (3).
3. Use a large flat-bladed tool in order to remove the automatic transaxle range selector cable (1) from the cable lever (5).
4. Use pliers in order to depress the cable retainers.
5. Remove the automatic transaxle range selector cable from the automatic transaxle range selector cable bracket (4).
6. Remove the knee bolster. Refer to «Knee Bolster, Insulator, Molding Replacement - Instrument Panel»(ref-241678-S36361698522006081100000) in Instrument Panel, Gages and Console.
7. Remove the retaining clip (4) from the automatic transaxle range selector cable (3).
8. Remove the automatic transaxle range selector cable (2) from the column control lever (1).
9. Remove the automatic transaxle range selector cable from the steering column bracket (5).
10. Remove the automatic transaxle range selector cable through the hole in the cowl.

Installation Procedure

1. Properly route the automatic transaxle range selector cable through the engine compartment.
2. Install the automatic transaxle range selector cable through the cowl.
3. Install the automatic transaxle range selector cable to the steering column bracket (5).
4. Install the retaining clip (4) to the automatic transaxle range selector cable (3).
5. Install the automatic transaxle range selector cable (2) to the column control lever (1).
6. Install the knee bolster. Refer to «Knee Bolster, Insulator, Molding Replacement - Instrument Panel»(ref-241678-S36361698522006081100000) in Instrument Panel, Gages and Console.
7. Install the automatic transaxle range selector cable to the automatic transaxle range selector cable bracket (4).
8. Install the automatic transaxle range selector cable (1) to the automatic transaxle range selector lever (5).
9. Install the retaining clip (2) to the automatic transaxle range selector cable (3).
10. Adjust the automatic transaxle range selector cable. Refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-241713-S17059604272006081100000) .
11. Install the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).
2. Use a flat-bladed tool in order to remove the automatic transaxle range selector cable from the cable lever and the bracket. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-241713-S35882788832006081100000) .
3. Remove the automatic transaxle range selector cable bracket bolts.
4. Remove the automatic transaxle range selector cable bracket.

1. Install the automatic transaxle range selector cable bracket.
2. Install the automatic transaxle range selector cable bracket bolts. Tighten: Tighten the automatic transaxle range selector cable bracket bolts to 25 N.m (18 lb ft).
3. Install the automatic transaxle range selector cable to the cable lever and the bracket. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-241713-S35882788832006081100000) .
4. Adjust the automatic transaxle range selector cable. Refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-241713-S17059604272006081100000) .
5. Install the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).
2. Remove the automatic transaxle range selector lever cable from the cable lever.
3. Remove the automatic transaxle range selector lever nut.
4. Remove the automatic transaxle range selector lever.

1. Install the automatic transaxle range selector lever.
2. Install the automatic transaxle range selector lever nut. Tighten: Tighten the automatic transaxle range selector lever nut to 32 N.m (23 lb ft).
3. Install the automatic transaxle range selector lever cable to the automatic transaxle range selector lever.
4. Install the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).

1. Remove the oil indicator from the filler tube.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
3. Remove the retaining nut from the EGR at the top of the filler tube.
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
5. Remove the lower retaining bolt at the base of the filler tube.
6. Remove the fluid filler tube.
7. Remove the fluid filler tube seal.

1. Install the fluid filler tube seal in the transaxle.
2. Position the fluid filler tube into the transaxle.
3. Install the fluid filler tube bracket bolt through the fluid filler tube bracket. Tighten: Tighten the bolt to 13 N.m (115 lb in).
4. Lower the vehicle.
5. At the top of the filler tube Install the retaining nut to the filler tube the EGR at the top of the filler tube.
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
7. Inspect for proper fluid level.
8. Inspect for fluid leaks.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
3. Remove the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
4. Disconnect the vehicle speed sensor wiring harness connector.
5. Remove the vehicle speed sensor bolt (9).
6. Remove the vehicle speed sensor (10) from the extension case.
7. Remove the O-ring seal (11) from the vehicle speed sensor (10).
8. Inspect the vehicle speed sensor and O-ring seal for the following: Damaged connector Cracked housing Signs of rotor damage Cuts or nicks on the O-ring seal (11)

1. Install the O-ring seal (11) to the vehicle speed sensor (10).
2. Install the vehicle speed sensor to the extension case.
3. Install the vehicle speed sensor bolt (9). Tighten: Tighten the bolt to 12 N.m (106 lb in).
4. Connect the vehicle speed sensor wiring harness connector.
5. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
6. Install the right front tire and wheel. «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
7. Lower the vehicle.

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).
2. Use a large flat-bladed tool in order to depress the reverse servo cover (40).
3. Use a small flat-bladed tool in order to remove the retaining ring (39).
4. Use a small flat-bladed tool in order to pull the O-ring seal (41) out through the slot in the case.
5. Use side cutting pliers in order to cut the servo cover O-ring seal (41).
6. Use a large flat-bladed tool in order to depress the reverse servo cover (40), grasp one end of the cut seal (41) and pull the seal (41) out of the servo cover (40).
7. Remove the reverse servo cover (40).
8. Remove the servo assembly (42-48).
9. Remove the servo spring (49).

1. Raise the driver (left) side of the vehicle until it is higher than the passenger (right) differential side. This ensures that the reverse band is in the proper location.
2. Install the servo spring (49).
3. Install the servo assembly (42-48).
4. Install the reverse servo cover (40) with the new O-ring seal (41).
5. Install the snap ring (39).
6. Install the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).

1. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L (LX9).
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
3. Remove the stabilizer shaft. Refer to «Stabilizer Shaft Replacement (FWD)»(ref-241710-S13642053022006081100000) or «Stabilizer Shaft Replacement (AWD)»(ref-241710-S00902690242006081100000) in Front Suspension.
4. Remove the power steering gear heat shield.
5. Remove the power steering gear from the frame. Refer to «Power Steering Gear Replacement»(ref-241712-S39953065112006081100000) in Power Steering System.
6. Use a strap in order to secure the power steering gear to the exhaust manifold.
7. Remove the power steering cooler line clamps from the frame. Refer to «Power Steering Cooler Pipe/Hose Replacement»(ref-241712-S22419227572006081100000) in Power Steering System.
8. Use wire in order to secure the power steering cooler line to an engine component.
9. Remove the engine mount nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) in Engine Mechanical - 3.5L (LX9).
10. Remove the transaxle mount nuts. Refer to «Automatic Transmission Mount Replacement»(ref-241713-S11891386862006081100000) .
11. Use a utility stand in order to support the frame front.
12. Use a utility stand in order to support the frame rear.
13. Remove the frame bolts.
14. Use the utility stand in order to lower the frame rear for access to the forward servo cover.
15. Position a drain pan under the forward servo cover.
16. Remove the forward band servo cover bolts.
17. Remove the forward servo cover.
18. Remove the forward servo cover O-ring.
19. Remove the servo piston assembly.
20. Remove the servo spring.

1. Install the servo spring.
2. Install the servo piston assembly.
3. Install the forward servo cover O-ring.
4. Install the forward servo cover.
5. Install the forward band servo cover bolts. Tighten: Tighten the bolts to 12 N.m (106 lb in).
6. Remove the drain pan from under the forward servo cover.
7. Use the utility stand in order to raise the frame rear.
8. Install the NEW frame bolts.
9. Adjust the utility straps as necessary in order to align the powertrain mounts with the frame.
10. Install the transaxle mount nuts. Refer to «Automatic Transmission Mount Replacement»(ref-241713-S11891386862006081100000) .
11. Install the engine mount nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) in Engine Mechanical - 3.5L (LX9).
12. Install the power steering gear to the frame. Refer to «Power Steering Gear Replacement»(ref-241712-S39953065112006081100000) in Power Steering System.
13. Install the power steering gear heat shield.
14. Install the stabilizer shaft. Refer to «Stabilizer Shaft Replacement (FWD)»(ref-241710-S13642053022006081100000) or «Stabilizer Shaft Replacement (AWD)»(ref-241710-S00902690242006081100000) in Front Suspension.
15. Lower the vehicle.
16. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L (LX9).
17. Adjust the fluid level. Refer to the following information: «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) in Maintenance and Lubrication. «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000) in Maintenance and Lubrication.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the left front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
3. Remove the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
4. Remove the left stabilizer shaft links from the left lower control arm. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) in Front Suspension.
5. Remove the left tie rod end from the left steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-241712-S26292995872006081100000) in Power Steering System.
6. Remove the left lower ball joint from the lower control arm. Refer to «Lower Ball Joint Replacement»(ref-241710-S21332829452006081100000) in Front Suspension.
7. Remove the left wheel drive shaft from the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
8. Reposition and secure the left wheel drive shaft to the left steering knuckle and strut.
9. Using the J 6125-B with the J 6125-1B and the J 23129 remove the wheel drive shaft oil seal (1) from the transmission.

1. Use a light wipe of transaxle fluid to lubricate the seal lip.
2. Install the J 37292-B into the new seal (409). See «Special Tools»(ref-241713-S11115775082006081100000) .
3. Using the J 34115 install a new seal (409). See «Special Tools»(ref-241713-S11115775082006081100000) .
4. Install the wheel drive shaft to the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
5. Remove the J 37292-B . See «Special Tools»(ref-241713-S11115775082006081100000) .
6. Install the left lower ball joint to the lower control arm. Refer to «Lower Ball Joint Replacement»(ref-241710-S21332829452006081100000) in Front Suspension.
7. Install the left tie rod end to the left steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-241712-S26292995872006081100000) in Power Steering System.
8. Install the left stabilizer shaft links to the left lower control arm. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) in Front Suspension.
9. Install the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
10. Install the left front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
11. Lower the vehicle.
12. Refill the automatic transmission with automatic transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) .
13. Inspect for automatic transmission fluid leaks. Refer to «Fluid Leak Diagnosis»(ref-241746-S32736358022006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
3. Remove the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
4. Remove the right stabilizer shaft links from the right lower control arm. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) in Front Suspension.
5. Remove the right tie rod end from the right steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-241712-S26292995872006081100000) in Power Steering System.
6. Remove the right lower ball joint from the lower control arm. Refer to «Lower Ball Joint Replacement»(ref-241710-S21332829452006081100000) .
7. Remove the right wheel drive shaft from the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
8. Reposition and secure the right wheel drive shaft to the right steering knuckle and strut.
9. Using the J 6125-B with the J 6125-1B and the J 23129 remove the wheel drive shaft oil seal (1) from the transmission.

1. Use a light wipe of transaxle fluid to lubricate the seal lip.
2. Install the J 37292-B into the new seal (4). See «Special Tools»(ref-241713-S11115775082006081100000) .
3. Using the J 29130 install the new seal (4). See «Special Tools»(ref-241713-S11115775082006081100000) .
4. Install the wheel drive shaft to the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
5. Install the right lower ball joint to the steering knuckle. Refer to «Lower Ball Joint Replacement»(ref-241710-S21332829452006081100000) in Front Suspension.
6. Install the right tie rod end to the steering knuckle. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(ref-241712-S26292995872006081100000) in Power Steering System.
7. Install the right stabilizer shaft links to the right lower control arm. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) in Front Suspension.
8. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
9. Install the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
10. Lower the vehicle.
11. Refill the automatic transmission with automatic transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) .
12. Inspect for automatic transmission fluid leaks. Refer to «Fluid Leak Diagnosis»(ref-241746-S32736358022006081100000) .

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).
2. Remove the pressure test hole plug (38).

1. Install the pressure test hole plug (38). Tighten: Tighten the plug (38) to 12 N.m (106 lb in).
2. Install the throttle body air inlet duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).

1. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).
2. Use a hammer and a chisel in order to raise the transaxle vent seat off of the transaxle.
3. Use a flat-bladed tool in order to pry the transaxle vent (37) out of the transaxle.

1. Use a small hammer and a flat-bladed tool and tap down on the transaxle vent seat in order to install the transaxle vent (37).
2. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(ref-241686-S30580330962006081100000) in Engine Controls - 3.5L (LX9).

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Place a drain pan under the transaxle bottom oil pan
3. Remove the oil pan bolts from the front.
4. Remove the oil pan bolts from the sides.
5. Loosen the oil pan rear bolts approximately four turns.
6. Use a rubber mallet to lightly tap the oil pan or use a flat-bladed tool in order to pry the oil pan loose.
7. Allow the fluid to drain.
8. Remove the remaining oil pan bolts.
9. Remove the oil pan (24).
10. Remove the oil pan gasket (25).
11. Inspect the oil pan and the filter screen for the following foreign material: Inspect for metal particles. Inspect for clutch facing material. Inspect for rubber particles. Inspect for engine coolant.
12. Determine the source of the contamination if foreign material is evident.
13. Correct the source of the contamination.
14. Inspect the oil pan flange for distortion (1).
15. Straighten the oil pan flange (1) if distorted.
16. Inspect the washers on the bolts when service requires the removal of the bottom oil pan.
17. Install a new bolt and washer assembly if the washer is inverted.
18. Inspect the oil pan (24) for the following conditions: A damaged sealing surface A dented or cracked bottom surface
19. Inspect the oil pan gasket (25) for the following conditions: A bent or damaged seal core A damaged rubber seal surface
20. Inspect the oil pan magnet (26) for the following conditions: Damage Misalignment
21. Clean the oil pan, the gasket and the magnet in order to remove any sediment.
22. Clean the case sealing surface and the pan sealing surface. Ensure all traces of the old gasket material are removed.
23. Allow the case sealing surface and the pan sealing surface to dry completely.

1. Install the oil pan gasket (25).
2. Install the oil pan (24).
3. Install the oil pan bolts (23). Tighten: Tighten the oil pan bolts (23) to 14 N.m (10 lb ft).
4. Lower the vehicle.
5. Adjust the fluid level. Refer to the following information. «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) in Maintenance and Lubrication. «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000) in Maintenance and Lubrication.
6. Inspect for fluid leaks.

1. Remove the oil pan and the gasket. Refer to «Oil Pan Replacement»(ref-241713-S21097235832006081100000) .
2. Remove the filter (100). Remove the lip ring seal pressed into the case only if replacement is necessary.
3. Inspect the screen for the following foreign material: Inspect for metal particles. Inspect for clutch facing material. Inspect for rubber particles. Inspect for engine coolant.
4. Determine the source of the contamination if foreign material is evident. Repair as necessary.
5. Clean the screen and allow the screen to dry completely.

1. If removed, install a new seal (101).
2. Install the filter (100).
3. Install the gasket and the oil pan. Refer to «Oil Pan Replacement»(ref-241713-S21097235832006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-241713-S21097235832006081100000) .
3. Remove the filter. Refer to «Oil Filter and Seal Replacement»(ref-241713-S04319425202006081100000) .
4. Remove the accumulator bolts (131).
5. Remove the manual 2-1 band servo cover bolts (103).
6. Use a large flat-bladed tool in order to gently pry the lube oil pipe retainer (129) from the case.
7. Remove the lube oil pipe (130) from the front differential carrier internal gear lube hole.
8. Remove the accumulator (132).
9. Remove the manual 2-1 band servo cover (104).
10. Remove the manual 2-1 band servo (106-116).
11. Remove the manual 2-1 band servo cover gasket (105).
12. To disassemble, inspect and service the accumulator and manual 2-1 band servo, refer to the «TRANSFER CASE - STEYR (OVERHAUL)»(ref-246424) .

1. Install the manual 2-1 band servo cover gasket (105) into the case. Lubricate the manual 2-1 band servo cover gasket with automatic transmission fluid.
2. Install the manual 2-1 band servo (106-116).
3. Install the manual 2-1 band servo cover (104).
4. Install the manual 2-1 band servo cover bolts (103). Tighten: Tighten the bolts (103) to 25 N.m (18 lb ft).
5. Install the accumulator (132).
6. Install the lube oil pipe (130) into the case at the lube hole for the front differential carrier internal gear.
7. Use a flat-bladed tool in order to lock the lube oil pipe retainer (129) into the case.
8. Install the accumulator bolts (131). Tighten: Tighten the bolts (131) to 12 N.m (106 lb in).
9. If removed, install a new filter seal.
10. Install the filter. Refer to «Oil Filter and Seal Replacement»(ref-241713-S04319425202006081100000) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(ref-241713-S21097235832006081100000) .
12. Lower the vehicle.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(ref-241713-S21097235832006081100000) .
2. Remove the thermo element pins and washers (120 and 123).
3. Remove the thermo element (121) and the thermo element plate (122).

1. Use the J 34094-A to set the middle thermo pin (123). See «Special Tools»(ref-241713-S11115775082006081100000) .
2. Install the new thermo element plate (122).
3. Install the pin and washer (120).
4. Use the J 34094-A to set the height of the pin and washer (120) furthest from the accumulator. See «Special Tools»(ref-241713-S11115775082006081100000) .
5. Use the J 34094-A to set the height of the second pin and washer (120). See «Special Tools»(ref-241713-S11115775082006081100000) .
6. Carefully install the thermo element (121) between the two pin and washers (120). The V in the thermo element (121) must contact the thermo element plate (122).
7. Install the oil pan. Refer to «Oil Pan Replacement»(ref-241713-S21097235832006081100000) .
8. Refill fluid as necessary. Refer to «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve(s) (315A, 315B, 322, 334 and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391).
3. Remove the wiring harness (224).
4. Remove the clips retaining the solenoid(s).

1. Connect the wiring harness (224).
2. Install the wiring harness to the solenoid valve(s) (315A, 315B, 322, 334 and/or 440), TFP manual valve position switch (395) and/or the temperature sensor (391).
3. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the throttle body air inlet duct. Refer to «Air Cleaner Element Replacement»(ref-241686-S37324579822006081100000) .
2. Remove the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
3. Remove the wiper module cover.
4. Disconnect the 20-way electrical connector at the transaxle.
5. Remove the shift cable bracket from the transaxle. Refer to «Automatic Transmission Range Selector Cable Bracket Replacement»(ref-241713-S37197026682006081100000) .
6. Install the engine support fixture and support the engine/transaxle assembly. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) .
7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) .
8. Remove the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
9. Disconnect the left wheel speed sensor harness connector (1).
10. Remove the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
11. Remove both stabilizer shaft links from the lower control arms. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) .
12. Remove the wheel speed sensor harness from the control arm (1).
13. Remove the left lower ball joint from the left steering knuckle. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) .
14. Remove the left drive axle from the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) .
15. Reposition and secure the drive axle.
16. Remove the heat shield bolts from the frame. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) .
17. Remove the steering gear-to-frame bolts and secure the steering gear.
18. Support the left side of the frame with a utility stand.
19. Remove the transaxle mount lower nuts only. Refer to «Automatic Transmission Mount Replacement»(ref-241713-S11891386862006081100000) .
20. Loosen the engine mount lower nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) .
21. Remove the air deflector. Refer to «Radiator Air Baffle Assemblies and Deflectors»(ref-241700-S36931602902006081100000) .
22. Remove only the left side frame bolts. DO NOT LOOSEN the right side frame-to-body bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) .
23. Use the utility stand in order to lower the left side of the frame.
24. Position a drain pan under the transaxle.
25. Remove the utility stand and lower the vehicle.
26. Loosen the right engine support bolts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) .
27. Raise the vehicle.
28. Remove the transaxle mount bracket. Refer to «Automatic Transmission Mount Bracket Replacement»(ref-241713-S40517786322006081100000) .
29. Remove the transaxle wiring harness connectors.
30. Remove the case side cover bolts (56-58).
31. Remove the case side cover pan (53).
32. Remove the case side cover gasket (54).
33. Remove the case side cover inner gasket (59).
34. Inspect the case side cover (53) for the following conditions: Damaged or porous gasket sealing surfaces Damaged or porous casting surfaces Damaged or stripped bolt holes
35. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are reusable if they are NOT damaged.
36. Clean the case side cover.
37. Clean the case side cover gasket surfaces.

1. Install the case side cover inner gasket (59).
2. Install the case side cover gasket (54).
3. Install the case side cover pan (53).
4. Install the case side cover bolts (56-58). Tighten: Tighten the bolts (56-58) to 25 N.m (18 lb ft).
5. Install the transaxle mount bracket. Torque: Torque to 95 N.m (70 lb ft).
6. Remove the drain pan from under the transaxle.
7. Install the wiring harness connectors.
8. Use the utility stand in order to raise the left side of the frame.
9. Install the left side frame bolts. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) . Tighten: Tighten the bolts to 165 N.m (122 lb ft).
10. Install the transaxle mount. Refer to «Automatic Transmission Mount Replacement»(ref-241713-S11891386862006081100000) .
11. Remove the utility stand support from the left side of the frame.
12. Install the air deflector. Refer to «Radiator Air Baffle Assemblies and Deflectors»(ref-241700-S36931602902006081100000) .
13. Install the left drive axle to the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) .
14. Install the left lower ball joint to the left steering knuckle. Refer to «Steering Knuckle Replacement»(ref-241710-S23526982342006081100000) .
15. Install two steering gear bolts. Tighten: Tighten the bolts to 80 N.m (59 lb ft).
16. Install the heat shield. Refer to «Power Steering Gear Heat Shield Replacement»(ref-241712-S24640446892006081100000) .
17. Install the lower ball joint nut and tighten.
18. Install and connect the wheel speed sensor harness (1).
19. Tighten the engine mount lower nuts. Refer to «Engine Mount Replacement - Right»(ref-241709-S34920493372006081100000) .
20. Install the stabilizer shaft links to the lower control arms. Refer to «Stabilizer Shaft Link Replacement (FWD)»(ref-241710-S04940231792006081100000) or «Stabilizer Shaft Link Replacement (AWD)»(ref-241710-S41656604822006081100000) . Tighten: Tighten to 23 N.m (17 lb ft).
21. Install the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) .
22. Install the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) .
23. Lower the vehicle.
24. Remove the engine support fixture from the engine/transaxle assembly. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) .
25. Install the shift cable bracket. Refer to «Automatic Transmission Range Selector Cable Bracket Replacement»(ref-241713-S37197026682006081100000) .
26. Connect the 20-way transmission electrical connector.
27. Install the engine mount struts. Refer to «Engine Mount Strut Replacement - Left»(ref-241709-S09230890912006081100000) and «Engine Mount Strut Replacement - Right»(ref-241709-S29966733752006081100000) .
28. Install the throttle body air inlet duct. Refer to «Air Cleaner Element Replacement»(ref-241686-S37324579822006081100000) .
29. Install the wiper module cover.
30. Adjust the fluid level. Refer to the following information. «Line Pressure Check Procedure»(ref-241746-S07795848482006081100000) «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000)
31. Inspect for proper completion of the repairs.
32. Inspect for fluid leaks.

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Remove the wiring harness assembly from the fluid temperature sensor (391).
3. Remove the fluid temperature sensor (391).

1. Install the fluid temperature sensor (391).
2. Install the wiring harness assembly to the fluid temperature sensor (391).
3. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Disconnect the transaxle wiring harness.
3. Remove the torque converter clutch PWM solenoid (334).

1. Install the torque converter clutch PWM solenoid (334).
2. Connect the transaxle wiring harness.
3. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Disconnect the transaxle wiring harness.
3. Remove the 1-2 shift solenoid (315A).

1. Install the 1-2 shift solenoid (315A).
2. Connect the transaxle wiring harness.
3. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Disconnect the transaxle wiring harness.
3. Using a small screwdriver or pick, remove the 2-3 shift solenoid valve retainer (314C) from the control valve body (301).
4. Remove the 2-3 shift solenoid (315B).
5. remove the O-ring seal (316) from the 2-3 shift solenoid valve (315B) ONLY if it is damaged.

1. Install a new O-ring seal (316) onto the 2-3 shift solenoid valve (315B) if the O-ring was removed.
2. Install the 2-3 shift solenoid (315B).
3. Install the 2-3 shift solenoid valve retainer (314C) into the control valve body (301).
4. Connect the transaxle wiring harness.
5. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Disconnect the transaxle wiring harness.
3. Remove the input speed sensor clip (441) from the case cover.
4. Remove the input speed sensor (440) from the case cover.
5. Inspect the input speed sensor (440) for the following conditions: Damaged or missing magnet Damaged housing Bent or missing electrical terminals Damaged speed sensor clip (441)

1. Install the input speed sensor (440) into the case cover.
2. Install the input speed sensor clip (441) into the case cover.
3. Connect the transaxle wiring harness.
4. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000)
2. Disconnect the transaxle wiring harness.
3. Remove the pressure control solenoid (322).

1. Install the pressure control solenoid (322).
2. Connect the transaxle wiring harness.
3. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Disconnect the transaxle wiring harness.
3. Remove the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300).
4. Carefully remove the fluid pressure manual valve position switch. Handle the switch carefully, the fluid pressure manual valve position switch is very delicate.
5. Inspect the fluid pressure manual valve position switch (395) for the following conditions: Damaged electrical connector terminals Damaged seals Damaged switch membranes Debris on the switch membranes

1. Carefully install the fluid pressure manual valve position switch. Handle the switch carefully, the fluid pressure manual valve position switch is very delicate.
2. Install the control valve body bolts (375, 379 and 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Tighten: Tighten the control valve body bolt (375) to 12 N.m (106 lb in). Tighten the control valve body bolt (379) to 16 N.m (12 lb ft). Tighten the control valve body bolt (381) to 8 N.m (70 lb in).
3. Connect the transaxle wiring harness.
4. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Remove the oil pump bolts (205-207).
3. Remove the oil pump (200) from the valve body (300).
4. Clean and inspect the oil pump.

1. Install the oil pump (200) to valve body (300).
2. Install the oil pump bolts (205-207). Tighten: Tighten the M6 X 1.0 X 20 bolt to 8 N.m (70 lb in). Tighten the M6 X 1.0 X 85 bolt to 12 N.m (106 lb in). Tighten the M6 X 1.0 X 95 bolt to 16 N.m (11 lb ft).
3. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000)

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Remove the oil pump. Refer to «Oil Pump Replacement»(ref-241713-S19359339602006081100000) .
3. Remove the valve body bolts (374-381, 384).
4. Remove the valve body (300) while keeping the spacer plate (370) with the transaxle.
5. Remove the ball check valves (372, 373) from the valve body.
6. Remove the spacer plate (370) and gasket.
7. Remove the ball check valves (372) from the case cover.
8. Inspect each check valve seat in the spacer plate (370) for excessive peening. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible light between the valve and the seat.
9. Inspect all components removed from the transaxle. Refer to «TRANSFER CASE - STEYR (OVERHAUL)»(ref-246424) .

1. Install the ball check valves (372) into the case cover. Use the J 36850 to retain the ball check valves in their proper locations.
2. Install the gasket and the spacer plate (370).
3. Install the ball check valves (372, 373) into the valve body. Use the J 36850 to retain the ball check valves in their proper locations.
4. Install the gasket (371) and the valve body (300).
5. Install the valve body bolts (374, 381, 384). Tighten: Tighten the M6 X 1.0 X 20 bolt to 8 N.m (70 lb in). Tighten the M6 X 1.0 X 30 bolt to 12 N.m (106 lb ft). Tighten the M6 X 1.0 X 45 bolt to 12 N.m (106 lb in). Tighten the M6 X 1.0 X 55 bolt to 12 N.m (106 lb in). Tighten the M6 X 1.0 X 60 bolt to 12 N.m (106 lb in). Tighten the M6 X 1.0 X 65 bolt to 12 N.m (106 lb in). Tighten the M6 X 1.0 X 85 bolt to 12 N.m (106 lb in). Tighten the M6 X 1.0 X 95 bolt to 16 N.m (12 lb ft). Tighten the M8 X 1.25 X 90 bolt to 25 N.m (18 lb ft).
6. Install the oil pump. Refer to «Oil Pump Replacement»(ref-241713-S19359339602006081100000) .
7. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Remove the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .
2. Remove the oil reservoir weir (27).

1. Install the oil reservoir weir (27).
2. Install the case side cover. Refer to «Case Side Cover Replacement»(ref-241713-S25661520052006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Disconnect the right drive axle from the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
3. Remove the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
4. Remove the vehicle speed sensor. Refer to «Input Speed Sensor Replacement»(ref-241713-S24594806202006081100000) .
5. Remove the case extension housing bolts (5).
6. Remove the case extension housing (6) with the axle seal and the O-ring (8).
7. Inspect the case extension housing (6) for the following conditions: A damaged or porous sealing surface for the case extension seal A damaged or porous sealing surface for the vehicle speed sensor A damaged or porous sealing surface for the right drive axle oil seal A damaged or porous sealing surface for the case extension housing A damaged or worn differential carrier bushing or output shaft bearing Damaged bolt holes Inspect the drive axle seal and replace if necessary

1. If removed, install the drive axle seal.
2. Install the case extension housing (6) with the axle seal and with the O-ring (8).
3. Install the case extension housing bolts (5). Tighten: Tighten the bolts (5) to 36 N.m (27 lb ft).
4. Install the vehicle speed sensor. Refer to «Input Speed Sensor Replacement»(ref-241713-S24594806202006081100000) .
5. Install the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
6. Connect the right drive axle to the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
7. Lower the vehicle.
8. Adjust the fluid level. Refer to the following information. «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) . «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) in Maintenance and Lubrication «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000) in Maintenance and Lubrication
9. Inspect for completion of the repairs.
10. Inspect for fluid leaks.

1. Remove the case extension housing. Refer to «Case Extension Housing Replacement»(ref-241713-S27570420502006081100000) .
2. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position.
3. Place the J 42562 between the end of the output shaft and the differential pinion shaft. See «Special Tools»(ref-241713-S11115775082006081100000) .
4. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear.
5. Remove the differential carrier (700).
6. Using snap ring pliers remove the compression ring (509) from the output shaft.
7. Remove the sun gear thrust bearing (698) from the differential carrier sun gear. The bearing may be stuck to the differential carrier.
8. Remove the differential carrier sun gear (697).
9. Remove the park gear (696).
10. Remove the internal gear thrust bearing (695) from the differential carrier internal gear.
11. Remove the sun gear shaft (689).
12. Inspect the sun gear shaft (689) for damage.

1. Assemble the sun gear thrust bearing (698), the differential carrier sun gear (697), the park gear (696), the internal gear thrust bearing (695) and the sun gear shaft (689) into the differential carrier (700).
2. Install the differential carrier into the case.
3. Install the case extension housing. Refer to «Case Extension Housing Replacement»(ref-241713-S27570420502006081100000) .

1. Remove the case extension housing. Refer to «Case Extension Housing Replacement»(ref-241713-S27570420502006081100000) .
2. Disconnect the left drive axle from the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.
3. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position.
4. Place the J 42562 between the end of the output shaft and the differential pinion shaft. See «Special Tools»(ref-241713-S11115775082006081100000) .
5. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear.
6. Remove the differential carrier (700).
7. Using snap ring pliers remove the compression ring from the output shaft.
8. Remove the output shaft through the left wheel opening.
9. Inspect the output shaft (510) and the bearing (511) for the following: A cracked or deformed bearing cage Damaged bushing journals Stripped splines A damaged retainer ring groove

1. Install the drive axle retaining ring (509) and the output shaft differential inboard snap ring (512) onto the output shaft (510).
2. Install the fourth clutch bearing (511) onto the output shaft (510).
3. Hold the front differential carrier in place and carefully install the output shaft (510) into the transmission through the left wheel opening. Extend the output shaft through the differential side gear.
4. Install the case extension housing. Refer to «Case Extension Housing Replacement»(ref-241713-S27570420502006081100000) .
5. Connect the left drive axle to the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Wheel Drive Shafts.

1. Disconnect the transaxle oil cooler (TOC) outlet hose from top side of the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
3. Remove the TOC hose retainer bolt.
4. Position a drain pan below the oil cooler hoses.
5. Disconnect the TOC outlet hose from the transaxle. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
6. Disconnect the TOC inlet hose from the transaxle. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
7. Disconnect the TOC inlet hose from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
8. Disconnect the TOC hoses from the radiator support retainer.
9. Remove the TOC hoses from the vehicle.

Note. Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss.

1. Install the TOC hoses to the vehicle.
2. Connect the TOC hoses to the radiator support retainer.
3. Connect the TOC inlet hose to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
4. Connect the TOC inlet hose to the transaxle. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
5. Connect the TOC outlet hose to the transaxle. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
6. Install the TOC hose retainer and the bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
7. Lower the vehicle.
8. Connect the TOC outlet hose to the top side of the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-241713-S21572432912006081100000) .
9. Adjust the fluid level. Refer to the following information. «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) . «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) in Maintenance and Lubrication. «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000) in Maintenance and Lubrication.

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-241746-S15551101122006081100000) .

Note. Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Position the drain pan.
3. Remove the transaxle oil cooler hoses from the transaxle oil cooler fittings. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(ref-241713-S35190635712006081100000) .
4. Remove the transaxle oil cooler fittings (28, 29) from the transaxle.

1. Apply sealant GM P/N 12345382 or equivalent to transaxle oil cooler fittings.
2. Install the transaxle oil cooler fittings (28, 29) to the transaxle. Tighten: Tighten the fittings to 38 N.m (28 lb ft).
3. Install the transaxle oil cooler hoses to the transaxle oil cooler fittings. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(ref-241713-S35190635712006081100000) .
4. Lower the vehicle.
5. Adjust the fluid level. Refer to the following information. «Transmission Fluid Checking Procedure»(ref-241746-S15551101122006081100000) «Fluid and Lubricant Recommendations»(ref-241726-S27699792622006081100000) in Maintenance and Lubrication. «Capacities - Approximate Fluid»(ref-241726-S15530288522006081100000) in Maintenance and Lubrication
6. Inspect for proper completion of the repairs.
7. Inspect for fluid leaks.

1. Remove the transaxle mount bracket. Refer to «Automatic Transmission Mount Bracket Replacement»(ref-241713-S40517786322006081100000) .
2. Remove the transaxle mount lower nuts to the transaxle mount frame bracket.
3. Remove the transaxle mount from the transaxle mount frame bracket.

1. Install the transaxle mount to the transaxle mount frame bracket.
2. Install the transaxle mount lower nuts to the transaxle mount frame bracket. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
3. Install the transaxle mount bracket to the transaxle. Refer to «Automatic Transmission Mount Bracket Replacement»(ref-241713-S40517786322006081100000) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
3. Remove the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
4. Remove the transaxle brace bolts.
5. Remove the transaxle brace.

1. Position the transaxle brace to transaxle and engine.
2. Hand start the bolts to the engine.
3. Hand start the bolts to the transaxle.
4. Install the brace bolts to the engine. Tighten: Tighten the bolts to 43 N.m (32 lb ft).
5. Install the brace bolts to the transaxle. Tighten: Tighten the bolts to 43 N.m (32 lb ft).
6. Install the right engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
7. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
8. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the transaxle brace bolts (2, 3).
3. Remove the transaxle brace (1).

1. Position the transaxle brace (1) to transaxle and engine.
2. Install the brace bolts (2, 3). Tighten: Tighten the bolts to 43 N.m (32 lb ft).
3. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the transaxle brace bolts (2-4).
3. Remove the transaxle brace (1).

1. Position the transaxle brace (2-4) to transaxle and engine.
2. Install the brace bolts (1). Tighten: Tighten the bolts to 43 N.m (32 lb ft).
3. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
3. Remove the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
4. Use a utility stand with a block of wood in order to support the transaxle.
5. Remove the transaxle mount upper nuts.
6. Remove the transaxle mount bracket bolts.
7. Remove the transaxle mount bracket.

1. Position the transaxle mount bracket.
2. Install the transaxle mount bracket bolts. Tighten: Start with the forward lower bolt and work clockwise to tighten the transaxle mount bracket bolts to 95 N.m (70 lb ft).
3. Remove the utility stand.
4. Install the transaxle mount upper nuts. Tighten: Tighten the nuts to 47 N.m (35 lb ft).
5. Install the left engine splash shield. Refer to «Splash Shield Replacement - Engine»(ref-241699-S36431278352006081100000) in Body Front End.
6. Install the left front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
7. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the transaxle brace (4). Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) or «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
3. Remove the torque converter cover bolts.
4. Remove the torque converter cover.

1. Install the torque converter cover.
2. Install the torque converter cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the transaxle brace (4). Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
4. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-241684-S36257494482006081100000) in General Information.
2. Remove the torque converter cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) .
3. Use the J 37096 in order to rotate the flywheel and access the torque converter bolts.
4. Use the J 37096 to hold the flywheel.
5. Remove the flywheel to torque converter bolts.

1. Install the flywheel to torque converter bolts.
2. Use the J 37623 to hold the flywheel. See «Special Tools»(ref-241713-S11115775082006081100000) . Tighten: Tighten the bolts to 63 N.m (47 lb ft).
3. Install the torque converter cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) .
4. Lower the vehicle.

1. Remove the push pins from the coolant recovery bottle.
2. Position aside coolant recovery bottle.
3. Remove air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
4. Remove the automatic transmission range selector cable (1) from the manual shaft (5).
5. Remove the automatic transmission range selector cable bracket (4). Refer to «Automatic Transmission Range Selector Cable Bracket Replacement»(ref-241713-S37197026682006081100000) .
6. Disconnect the wiring harness connector (3) from the transaxle.
7. Remove the wiring harness retainer from the side cover.
8. Remove the top 4 bell housing bolts (1, 2, 3) and stud (4).
9. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L (LX9).
10. Remove the frame. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
11. Remove the torque converter inspection cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) .
12. Use J 37096 in order to gain access to the torque converter bolts and prevent the flywheel from turning.
13. Remove the torque converter bolts.
14. Disconnect the vehicle speed sensor.
15. Remove the right and left axle shafts from the transmission. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Front Wheel Drive Shafts.
16. Disconnect the transmission cooler lines. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(ref-241713-S35190635712006081100000) .
17. Position the transmission jack under the transaxle.
18. Remove the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) or «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
19. Remove the lower transaxle bolt (6) and stud (5).
20. Remove the transaxle from the vehicle.
21. Flush the transaxle oil cooler pipes and the transaxle oil cooler.
22. Transfer all necessary parts as needed.

1. Align the transaxle filler tube to the transmission and Install the transaxle into the vehicle.
2. Install the lower transaxle bolt (6) and stud (5). Tighten: Tighten the bolt and stud to 75 N.m (55 lb ft).
3. Install the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
4. Install the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
5. Connect the transmission cooler lines. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(ref-241713-S35190635712006081100000) .
6. Install the right and left axle shafts into the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Front Wheel Drive Shafts.
7. Connect the vehicle speed sensor.
8. Install the torque converter bolts. Tighten: Tighten the bolts to 63 N.m (46 lb ft).
9. Install the torque converter inspection cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) .
10. Install the frame. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
11. Install the front wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
12. Lower vehicle.
13. Remove the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L (LX9)
14. Install the upper transaxle bolts (1, 2, 3) and stud (4). Tighten: Tighten the bolts and stud to 75 N.m (55 lb ft).
15. Connect the wiring harness (3) to the transaxle.
16. Install the transmission range selector cable bracket (4). Refer to «Automatic Transmission Range Selector Cable Bracket Replacement»(ref-241713-S37197026682006081100000) .
17. Install the automatic transmission range selector cable (1) on the manual shaft (5).
18. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
19. Install the coolant recovery bottle.
20. Adjust the fluid level. Refer to «Transmission General Specifications»(ref-241713-S37137857212006081100000) and «Fluid Capacity Specifications»(ref-241713-S00195674212006081100000) .
21. Inspect for fluid leaks.

1. Remove the push pins from the coolant recovery bottle.
2. Position aside coolant recovery bottle.
3. Remove air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
4. Remove the automatic transmission range selector cable (1) from the manual shaft (5).
5. Remove the automatic transmission range selector cable bracket (4). Refer to «Automatic Transmission Range Selector Cable Bracket Replacement»(ref-241713-S37197026682006081100000) .
6. Disconnect the wiring harness connector (3) from the transaxle.
7. Remove the wiring harness retainer from the side cover.
8. Remove the top 4 bell housing bolts (1, 2, 3) and stud (4).
9. Install the engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L (LX9).
10. Remove the prop shaft. Refer to «Propeller Shaft Replacement»(ref-241711-S04499692822006081100000) in Propeller Shaft.
11. Remove the engine to transfer case brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) or «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
12. Remove the frame. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
13. Remove the torque converter inspection cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) .
14. Use J 37096 in order to gain access to the torque converter bolts and prevent the flywheel from turning.
15. Remove the torque converter bolts.
16. Disconnect the vehicle speed sensor.
17. Remove the right and left axle shafts into the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Front Wheel Drive Shafts.
18. Disconnect the transmission cooler lines. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(ref-241713-S35190635712006081100000) .
19. Position the transmission jack under the transaxle.
20. Remove the transfer case to engine mount bolts. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
21. Remove the lower transaxle bolt (6) and stud (5).
22. Remove the transaxle from the vehicle.
23. Remove the transfer case from the transaxle. Refer to Transfer Case Removal in Transmission - 4T65-E Unit Repair.
24. The transmission-to-transfer case end play check procedure must be performed each time the transmission, transfer case or the internal components (excluding gaskets and seals) are replaced. Refer to Transmission to Transfer Case End Play Check (F4WD Only) in Transmission - 4T65-E Unit Repair.
25. Flush the transaxle oil cooler pipes and the transaxle oil cooler.
26. Transfer all necessary parts as needed.

1. The transmission-to-transfer case end play check procedure must be performed each time the transmission, transfer case or the internal components (excluding gaskets and seals) are replaced. Refer to Transmission to Transfer Case End Play Check (F4WD Only) in Transmission - 4T65-E Unit Repair.
2. Install the transfer case to the transaxle. Refer to Transfer Case Installation in Transmission - 4T65-E Unit Repair.
3. Position the flex plate alignment hole to the seven o'clock position.
4. Align the transaxle filler tube to the transmission and install the transaxle into the vehicle.
5. Install the lower transaxle bolt (6) and stud (5). Tighten: Tighten the bolt and stud to 75 N.m (55 lb ft).
6. Install transfer case to transmission bracket. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
7. Install the transaxle brace. Refer to «Automatic Transmission Brace Replacement (Front Wheel Drive)»(ref-241713-S14729348072006081100000) , «Automatic Transmission Brace Replacement (All Wheel Drive)»(ref-241713-S23714387282006081100000) or «Automatic Transmission Brace Replacement (Front Wheel Drive and All Wheel Drive)»(ref-241713-S32575647612006081100000) .
8. Connect the transmission cooler lines. Refer to «Automatic Transmission Oil Cooler Hose Replacement»(ref-241713-S35190635712006081100000) .
9. Install the right and left axle shafts into the transaxle. Refer to «Wheel Drive Shaft Replacement - Front»(ref-241734-S27456445772006081100000) in Front Wheel Drive Shafts.
10. Connect the vehicle speed sensor.
11. Install the torque converter bolts. Tighten: Tighten the bolts to 63 N.m (46 lb ft).
12. Install the torque converter inspection cover. Refer to «Torque Converter Cover Replacement»(ref-241713-S24745979452006081100000) .
13. Install the frame. Refer to «Frame Replacement - Front»(ref-241708-S16852767372006081100000) in Frame and Underbody.
14. Install the prop shaft. Refer to «Propeller Shaft Replacement»(ref-241711-S04499692822006081100000) in Propeller Shaft.
15. Install the propeller shaft-to-transfer case bolts (2). Ensure the special washer is in place on each pair of bolts. Tighten: Tighten the bolts to 33 N.m (24 lb ft).
16. Install the propeller shaft-to-torque tube bolts (4). Ensure the special washer is in place on each pair of bolts. Tighten: Tighten the bolts to 33 N.m (24 lb ft).
17. Install the front wheels. Refer to «Tire and Wheel Removal and Installation»(ref-241703-S14581567662006081100000) in Tires and Wheels.
18. Lower the vehicle.
19. Remove engine support fixture. Refer to «Engine Support Fixture»(ref-241709-S23878459562006081100000) in Engine Mechanical - 3.5L (LX9).
20. Install the upper transaxle bolts (1, 2, 3) and stud (4). Tighten: Tighten the bolts and stud to 75 N.m (55 lb ft).
21. Connect the wiring harness (3) to the transaxle.
22. Install the transmission range selector cable bracket (4). Refer to «Automatic Transmission Range Selector Cable Bracket Replacement»(ref-241713-S37197026682006081100000) .
23. Install the automatic transmission range selector cable (1) on the manual shaft (5).
24. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(ref-241686-S23045185402006081100000) in Engine Controls - 3.5L (LX9).
25. Install the coolant recovery bottle.
26. Adjust the fluid level. Refer to «Transmission General Specifications»(ref-241713-S37137857212006081100000) and «Fluid Capacity Specifications»(ref-241713-S00195674212006081100000) .
27. Inspect for fluid leaks.