Automatic Transmission Servicing (4L60-E): Removal & Installation GMC Savana H2500

REMOVAL & INSTALLATION

Removal

1. Raise and support the vehicle.
2. Remove transmission oil pan and filter. NOTE: 1-2 accumulator can be removed without removing the control valve assembly.
3. Remove control valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-154976-S00442672872003060300000).
4. Remove accumulator cover retaining bolts. (Scheme 85)
5. Remove 1-2 accumulator cover assembly.
6. Disassemble 1-2 accumulator by blowing compressed air into the 1-2 accumulator cover to remove the accumulator piston. Then remove the 1-2 accumulator inner and outer springs. (Scheme 86)
7. Inspect 1-2 accumulator inner and outer springs for cracks.
8. Remove 1-2 accumulator piston seal (1) from 1-2 accumulator piston. (Scheme 87) Then inspect 1-2 accumulator piston for porosity, cracks, scoring, nicks and scratches.
9. Inspect 1-2 accumulator cover for porosity, cracks, scoring, nicks and scratches.
10. Remove the spacer plate support retaining bolts. (Scheme 88) CAUTION: Use care not to drop the following items that will be removed along with the spacer plate: The number one checkball. The 3-4 accumulator spring. The 3-4 accumulator pin.
11. Remove the spacer plate support.
12. Remove the spacer plate to valve body gasket, spacer plate and spacer plate to transmission case gasket. (Scheme 89)
13. Remove the 3-4 accumulator piston and inspect the 3-4 accumulator spring for cracks. (Scheme 90)
14. Remove the 3-4 accumulator piston seal from the 3-4 accumulator piston and inspect for porosity, cracks, scoring, nicks and scratches.

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Installation

1. Install NEW 3-4 accumulator piston seal to 3-4 accumulator piston. (Scheme 87)
2. Install the 3-4 accumulator pin (1) into transmission case and retain the pin with Transjel(R) Lubricant (J-36850). (Scheme 91)
3. Install 3-4 accumulator piston onto the pin in the transmission case. Ensure that 3-4 accumulator piston legs face away from the transmission case. (Scheme 90)
4. Install the Pump and Valve Body Alignment Pin Set (J-25025-B) (2 and 3) to the transmission case. (Scheme 91)
5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate. Use Transjel(R) lubricant to retain gaskets to the spacer plate. The case gasket is identified by a "C". Be sure to place the case gasket on the transmission case side of the spacer plate. The valve body gasket is identified by a "V". Be sure to place the valve body gasket on the valve body side of the spacer plate.
6. Ensure that the solenoid screens (1 and 2) are in place on the spacer plate. (Scheme 92)
7. Place the checkball (3) on the spacer plate in the location shown.
8. Place the 3-4 accumulator spring (4) on the spacer plate.
9. Install the spacer plate and related components to the transmission.
10. Install the spacer plate support and the spacer plate support retaining bolts. (Scheme 88) Tighten spacer plate support retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. (Scheme 93)
12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston.
13. Install 1-2 accumulator inner and outer springs to 1-2 accumulator cover. (Scheme 94)
14. Install 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover.
15. Install 1-2 accumulator cover and accumulator cover retaining bolts. (Scheme 85) Tighten accumulator cover retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
16. Remove pump and valve body alignment pin set from transmission case.
17. Install control valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-154976-S00442672872003060300000).
18. Install transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION.
19. Lower the vehicle, and fill transmission to appropriate level with proper fluid. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.

Scheme 91

Scheme 92

Scheme 93

Scheme 94

1. Remove the grille assembly.
2. Place a drain pan under the vehicle.
3. Disconnect the transmission oil cooler lines from the auxiliary oil cooler.
4. Remove the oil cooler lines from the auxiliary oil cooler. See «OIL COOLER LINES»(ref-154976-S35937301572003060300000) .
5. Remove the 4 bolts securing the auxiliary oil cooler to the radiator support.
6. Remove the auxiliary oil cooler.

1. Install the 4 bolts securing the oil cooler to the radiator support. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000) .
2. Install the oil cooler lines to the auxiliary oil cooler. See «OIL COOLER LINES»(ref-154976-S35937301572003060300000) . Tighten the cooler lines to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000) .
3. Remove the drain pan.
4. Install the grille assembly.

Note. Do not remove the valve body for the following procedure. 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-154976-S19254344532003060300000) under LUBRICATION.
2. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY»(ref-154976-S19812479742003060300000).
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. see scheme 19 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
4. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 96)
5. Remove the 1-2 and 2-3 shift control solenoid retainers. Remove the 1-2 and 2-3 shift control solenoids. (Scheme 97)
6. Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 97)

Scheme 95

Scheme 96

Scheme 97

1. Install the 3-2 control solenoid. Install the 3-2 control solenoid retainer. (Scheme 97)
2. Install the 1-2 and 2-3 shift control solenoids. Install the 1-2 and 2-3 shift control solenoid retainers. (Scheme 97)
3. Install the pressure control solenoid. Ensure the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
4. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. see scheme 19 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 control solenoid.
5. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(ref-154976-S19812479742003060300000).
6. Install the oil filter and oil pan. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION.
7. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.

Raise and support the vehicle. Place drain pan under vehicle. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove the rear extension oil seal. Use a flat bladed tool and carefully pry the seal from the housing. (Scheme 98) Inspect case housing for damage. Replace extension housing if necessary.

Scheme 98

Lubricate inside diameter of the NEW seal with Transjel(R) Lubricant (J-36850). Install the new seal using seal installer and a soft faced mallet. (Scheme 99) Install the seal to the extension housing. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove drain pan and lower the vehicle. Fill transmission with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

Scheme 99

1. Remove the transmission fluid level indicator from the fluid fill tube. Remove engine cover. Remove the bolt securing the transmission fluid fill tube bracket to the engine. Raise and support the vehicle. Remove the bolt securing the transmission fluid fill tube bracket to the transmission. Remove the transmission pan drain plug. Drain the fluid into an approved container. (Scheme 100)
2. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. Remove the transmission fluid fill tube from the transmission.
3. Pull the tube upward from the transmission. Remove the transmission fill tube seal. Clean the metal parts using solvent. DO NOT allow the solvent to enter the transmission. Dry the parts using compressed air.

Scheme 100

1. Install a new filler tube seal into the transmission case. Install the filler tube into the seal. (Scheme 100)
2. Lower the vehicle. Install the upper transmission fill tube to the vehicle and into the lower fill tube. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
3. Install the bolt securing the filler tube bracket to the engine and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
4. Install the oil level indicator. Adjust fluid level as necessary. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.

1. Remove the upper oil cooler line from the radiator. Raise and support the vehicle. If equipped with AWD, remove the engine protector shield. Remove the lower cooler line from the radiator. (Scheme 101) NOTE: Perform the following procedures when removing the retaining ring and cooler line from the quick connect fitting on the radiator and transmission.
2. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 2 inches. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. (Scheme 102)
3. Remove the retaining ring from the quick connect fitting. Discard the retaining ring. Pull the cooler line straight out from the quick connect fitting. (Scheme 103)
4. Remove the retaining ring (E-clip) securing the cooler line to the quick connect to remove the remaining cooler lines from the remaining quick connect fittings. Remove the cooler lines from the vehicle.

Scheme 101

Scheme 102

Scheme 103

Note. Do not reuse any of the existing oil lines or oil line fittings if there is any 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 the transmission oil cooler line to the vehicle.
2. 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 104) Rotate the retaining ring around the fitting until the retaining ring is positioned with all 3 ears through the 3 slots on the fitting. (Scheme 105) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 106)
3. Ensure the 3 retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. (Scheme 107)
4. Install the new retaining rings (E-clips) into the remaining quick connect fittings. NOTE: Ensure 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.
5. Install the cooler lines to the vehicle. Install the cooler line into the quick connect fitting. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. (Scheme 108) NOTE: Do not use the plastic cap on the cooler line to install the cooler line into the fitting. (Scheme 109)
6. Pull back sharply on the cooler line to ensure the cooler line is fastened into the quick connect fitting. Position (snap) the plastic cap onto the fitting. (Scheme 110) DO NOT manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. Ensure the plastic cap is fully seated against the fitting.
7. Ensure no gap is present between the cap and the fitting. (Scheme 111) Ensure the Yellow identification band on the tube is hidden within the quick connect fitting. (Scheme 112) A hidden Yellow identification band indicates proper joint seating.
8. DO NOT install the cooler line end into the fitting incorrectly. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting per Step 5 of the cooler line removal procedure. Check the retaining ring and the tube end in order to ensure neither is bent. Replace the cooler line or the retaining ring if necessary, and reinstall per step 2 of the cooler line installation procedure.
9. Install the cooler lines into the retaining clip at the oil pan. Install the flair nut securing the lower oil cooler line to the radiator. Tighten the flair nuts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
10. Lower the vehicle. Install the flare nut securing the upper cooler line to the radiator. Tighten the flair nut to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000). Start the engine.

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Apply the parking brake. Shift the transmission into Neutral. Raise the vehicle.
2. Remove the nut securing the transmission control lever to the manual shaft. Remove the transmission control lever from the manual shaft. (Scheme 113)
3. Disconnect the wiring harness connector from the PNP switch.
4. Remove the bolts securing the PNP switch to the transmission. Remove the PNP switch from the manual shaft.

Scheme 113

1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. (Scheme 114) Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. CAUTION: 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.
2. Install the switch to the transmission with two bolts finger tight. (Scheme 114) Position the Neutral Position Adjustment Tool (J-41364-A) onto the park/neutral position switch. Ensure that the two slots on the switch where the manual shaft is inserted are lined up with the lower two tabs on the tool.
3. 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-154976-S18779490572003060300000).
4. Remove the neutral position adjustment tool from the switch. If installing a new switch, remove the positive assurance bracket at this time. Connect the electrical connectors to the switch.
5. Install the transmission control lever to the manual shaft with the nut. Tighten the control lever nut to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
6. Lower the vehicle. Check the switch for proper operation. The engine must start in the Park or Neutral positions only. If proper operation of the switch can not be obtained, replace the switch.
7. If vehicle does not operate as specified, readjust the PNP switch.

Scheme 114

1. Raise and support the vehicle. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION.
2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. (Scheme 115)
3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). (Scheme 116)
5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). Remove the pressure regulator valve (1). (Scheme 116)

Scheme 115

Scheme 116

1. Install the pressure regulator valve (1). Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). (Scheme 116)
2. Install the reverse boost valve (4) in the reverse boost valve sleeve (5). Install the reverse boost valve (4) and sleeve (5) in the oil pump cover. (Scheme 116)
3. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot.
4. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve. (Scheme 115) Install the transmission oil filter and oil pan. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION.
5. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.

1. Apply the parking brake. Position the steering column shift lever to Park. Remove the knee bolster trim panel.
2. Remove the clip securing the shift cable to the steering column bracket. Remove the shift cable from the steering column shift control. Pull back the carpet and insulation to gain access to the shift cable pass-through grommet.
3. Remove the rubber grommet from the floor panel. Raise the vehicle. see scheme 7
4. Remove the shift cable from the stud ball. Remove the locking clip from the cable at the bracket. Unclip the cable from the retainers at the fuel lines and body. Lower the vehicle. Remove the cable from the vehicle.

Note. Prior to installing the shift cable to the vehicle, ensure that the column shift lever and the transmission control lever are in the mechanical park position. The transmission control lever can be positioned to mechanical park by rotating the control lever clockwise until it reaches its full clockwise position.

1. Install the shift cable to the vehicle. Raise the vehicle. Remove the black shipping tab from the transmission end of the shift cable and discard the tab.
2. Install the shift cable to the transmission bracket. see scheme 7 Install the cable clip. Install the shift cable end to the transmission shift control lever by pushing the cable end onto the transmission shift control lever stud ball. Lock the primary lock. Lock the secondary lock. Attach the shift cable to the fuel line and body clips. Lower the vehicle. NOTE: Ensure the shift lever is in the Park position.
3. Install the rubber grommet to the floor panel. Install the shift cable to the steering column shift control. Install the clip securing the shift cable to the steering column bracket. Install the cable to the shift lever ball stud.
4. Adjust shift cable. See «SHIFT CABLE»(ref-154976-S10857048442003060300000) under ADJUSTMENTS. Install the knee bolster bracket. Install the knee bolster trim panel.

1. Raise and support the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION.
2. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 118) 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.
3. Remove the 1-2 accumulator assembly. DO NOT remove the spacer plate. See «ACCUMULATOR ASSEMBLY»(ref-154976-S19812479742003060300000).
4. Disconnect the internal wiring harness electrical connectors from the transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift control solenoid. (Scheme 117)
5. Remove the TCC PWM solenoid retainer. Remove the TCC PWM solenoid to access one of the TCC solenoid retaining bolts. (Scheme 119)
6. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. see scheme 44 Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 120)
7. Using power piston seal protector and diaphragm retainer installer, release the pass-through electrical connector from the transmission case. (Scheme 121) Use the small end of the power piston seal protector and diaphragm 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.
8. Remove the TCC solenoid (with "O" ring seal) and wiring harness assembly from the transmission case.
9. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage, cracked connectors, exposed wires and loose pins. see scheme 47

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

1. Install the wiring harness and TCC solenoid assembly with a new "O" ring seal to the transmission. Install the pass-through electrical connector to the transmission case. (Scheme 121)
2. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. (Scheme 120) Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
3. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
4. Install the pressure control solenoid. see scheme 44 Ensure the electrical tabs are facing outboard. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
5. Install the TCC PWM solenoid to the control valve body. (Scheme 119) Install the TCC PWM solenoid retainer.
6. Connect the internal wiring harness electrical connectors to the transmission fluid pressure switch, 1-2 shift control solenoid, 2-3 shift control solenoid, pressure control solenoid, TCC PWM solenoid and 3-2 shift control solenoid. (Scheme 86)
7. Install the 1-2 accumulator. 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 118)
8. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.

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. (Scheme 122) Torque converter clutch solenoid (1). Pressure control solenoid (2). Internal wiring harness (3). 2-3 shift control solenoid (4). 1-2 shift control solenoid (5). Transmission fluid pressure manual valve position switch (6). 3-2 shift control solenoid (7). Torque converter clutch pulse width modulation solenoid (8).
2. Remove the fluid level indicator. Raise and support the vehicle. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION.
3. Disconnect the internal wiring harness electrical connectors from the transmission fluid pressure manual valve position switch (1), 1-2 shift control solenoid (2), 2-3 shift control solenoid (3), pressure control solenoid (4), TCC PWM solenoid (5) and the 3-2 shift control solenoid (6).
4. Remove the fluid indicator stop bracket bolt. (Scheme 123) Remove the fluid indicator bracket (1). 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.
5. Remove the TCC PWM solenoid (1) to access the TCC solenoid retaining bolts. (Scheme 119) Remove the TCC solenoid retaining bolts. (Scheme 124) Remove the TCC solenoid (with "O" ring seal) and wiring harness from the control valve body.
6. Reposition the harness to the side of the transmission case. (Scheme 121) Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 125) Remove the transmission fluid pressure switch. Inspect the transmission fluid pressure switch for damage or debris. (Scheme 126)
7. Remove the manual detent spring retaining bolt. Remove the manual detent spring. (Scheme 127) Inspect the manual detent spring for cracks or damage. CAUTION: 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.
8. Remove the remaining control valve body bolts. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. (Scheme 128)
9. If disassembly of the control valve body is necessary, see appropriate OVERHAUL article.

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

1. Install the 7 checkballs in the valve body. (Scheme 129) Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 128)
2. Verify the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). (Scheme 130) 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 131) DO NOT install the transmission fluid indicator stop bracket and bolt at this time. NOTE: When installing bolts throughout this procedure, ensure to use the correct bolt size and length in the correct location as specified.
3. Install but do not tighten the control valve body bolts which retain only the valve body directly. (Scheme 132) 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).
4. Install the manual detent spring. Install but DO NOT tighten the manual detent spring retaining bolt. (Scheme 127) Install the transmission fluid pressure switch. (Scheme 125) Install but DO NOT tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 125) NOTE: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation.
5. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. (Scheme 132) Tighten the control valve body bolts (in sequence) to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
6. Ensure the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
7. Install the TCC solenoid with a new "O" ring seal to the valve body. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
8. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. Place the tab between the valve body and the pressure switch in the location shown (2). (Scheme 121) Press the harness into position on the valve body bolt bosses (1 and 3).
9. Install the TCC PWM solenoid (1) to the control valve body. Install the TCC PWM solenoid retainer (2). (Scheme 119)
10. Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 123) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000).
11. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch (1). (Scheme 95) The 1-2 shift control solenoid. The 2-3 shift control solenoid. The pressure control solenoid. The TCC PWM solenoid. The 3-2 shift control solenoid.
12. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-154976-S19254344532003060300000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Raise and support the vehicle. Remove the electrical connector from the speed sensor. Remove the bolt. (Scheme 133) Remove the speed sensor and the "O" ring seal. Inspect the seal and the transmission case. Replace the seal, if necessary.

Scheme 133

Install the speed sensor and the "O" ring seal into the transmission. (Scheme 133) Install the bolt. Tighten the bolt to specification. See TORQUE SPECIFICATIONS. Install the electrical connector to the speed sensor. Lower the vehicle. Check transmission fluid level and fill if necessary. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

1. Raise and support the vehicle. Remove the 2 heat shield retaining bolts and the heat shield from the transmission. Remove the oil pan bolt below and to the left of the 2-4 servo cover. Install the servo cover depressor to the oil pan rail. Tighten the bolt on the servo cover depressor in order to compress the servo cover. (Scheme 134)
2. Remove the servo cover retaining ring. (Scheme 135) Loosen the bolt on the servo cover depressor to release tension on the servo cover. 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. Cut and remove the "O" ring seal before removing the cover. (Scheme 136)
3. Remove the 2-4 servo assembly from the transmission. Inspect the 4th apply piston, the 2-4 servo converter, 2nd apply piston and the piston inner housing for cracks, scoring, burrs and nicks.

Scheme 134

Scheme 135

Scheme 136

1. Install the new seals on the pistons and the servo cover. Lubricate the seals with clean transmission fluid. Install the 2-4 servo assembly into the 2-4 servo bore. Install the servo cover and "O" ring seal.
2. Install the servo cover depressor. (Scheme 134) Tighten the bolt on the servo cover depressor in order to compress the servo cover. Install the servo cover retaining ring. Remove the servo cover depressor from the oil pan flange.
3. Install the oil pan bolt. Tighten the oil pan bolt to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000). Install the 2 heat shield retaining bolts and the heat shield from the transmission. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154976-S18779490572003060300000). Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-154976-S15704054642003060300000) and «FLUID CAPACITIES»(ref-154976-S05037042142003060300000) under LUBRICATION.