Automatic Transmission Servicing (4L80-E): Removal & Installation GMC Savana H2500

REMOVAL & INSTALLATION

Removal

1. Remove the grille assembly.
2. Disconnect the 2 lines from the auxiliary cooler.
3. Remove the lines from the push clips on the auxiliary cooler mounting bracket.
4. Raise the vehicle.
5. Remove the lower bolts from the auxiliary cooler mounting bracket.
6. Lower the vehicle.
7. Remove the upper bolts.
8. Remove the auxiliary oil cooler from the vehicle.

Installation

1. Install the oil cooler into the vehicle.
2. Install the upper bolts into the oil cooler bracket. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000) .
3. Raise the vehicle.
4. Install the lower bolts to the oil cooler bracket. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000) .
5. Lower the vehicle.
6. Connect the oil cooler lines to the auxiliary oil cooler.
7. Attach the oil cooler lines to the push clips in the mounting bracket.
8. Reinstall the grille assembly.

1. The following components can be serviced without removing the valve body from the transmission. Ensure that removal of the valve body is necessary before proceeding. (Scheme 230) The 2-3 solenoid (1). The internal wiring harness (2). The 1-2 shift solenoid (3). The transmission fluid temperature sensor (4). The transmission fluid pressure manual valve position switch (5). The pressure control solenoid (6). The Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid (7).
2. Remove the fluid level indicator. (Scheme 231)
3. Raise the vehicle.
4. Remove the oil pan, gasket and filter. See «DRAINING & REFILLING»(ref-156344-S39127061732003071400000) under LUBRICATION.
5. Disconnect the internal wire harness from the Transmission Fluid Pressure (TFP) manual valve position switch. CAUTION: Use care not to loose the 5 "O" rings that are located between the TFP manual valve position switch and the valve body.
6. Remove the control valve body bolts (1) that retain the TFP manual valve position switch (2) to the control valve body. (Scheme 232)
7. Remove the TFP manual valve position switch.
8. Disconnect the internal wiring harness electrical connectors from the remaining valve body electrical components.
9. Remove the lube oil pipe bolt (6) and retainer (7). (Scheme 233)
10. Remove the lube oil pipe (5). (Scheme 233)
11. Remove the bolts and remove the manual shaft detent spring (3). (Scheme 233) CAUTION: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in transmission case passages.
12. Remove the remaining control valve body bolts.
13. Carefully lower the valve body down from the transmission case. Use care not to drop the manual shaft valve.
14. Remove the control valve assembly (2) which includes the following: The accumulator housing assembly (1). (Scheme 233) The control valve assembly to the spacer plate gasket. The spacer plate.
15. Remove the manual valve (1) from the control valve body. (Scheme 234)
16. Inspect the manual valve for nicks and burrs.
17. Remove the spacer plate to case gasket (2) from the case. The gasket may stick to the spacer plate. (Scheme 235)
18. Remove the PWM screen (1) from the case passage. (Scheme 235)
19. Remove the manual 2-1 band servo assembly (1). (Scheme 236)
20. Remove the servo piston cushion spring (2). (Scheme 236)
21. Remove the manual 2-1 band servo piston pin retainer ring (4). (Scheme 237)
22. Remove the manual 2-1 band servo piston pin (1). (Scheme 237)
23. Remove the manual 2-1 band servo piston seal (2). (Scheme 237) CAUTION: Do not use a magnet in order to remove the checkballs. Using a magnet to remove the checkballs may magnetize the checkballs, causing metal particles to stick.
24. Remove the eight checkballs (nine checkballs for some models). (Scheme 238)

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

1. Install the 8 checkballs (9 checkballs for some models) into the control valve body. The checkball marked as number 2, is used on RCP, RDP, ZJP and ZLP models only. To hold the checkballs in place, use the Transjel(R) Lubricant (J-36850).
2. Install the PWM screen into the control valve body. (Scheme 239)
3. Install a new manual 2-1 band servo piston seal (2) onto the manual 2-1 band servo piston (3). (Scheme 237)
4. Install the manual 2-1 band servo piston pin (1) into the manual 2-1 band servo piston (3). (Scheme 237)
5. Install the manual 2-1 band servo piston pin retainer ring (4). (Scheme 237)
6. Install the manual 2-1 band servo piston cushion spring (2). (Scheme 236) CAUTION: Make certain that the tapered end of the manual 2-1 band servo piston pin contacts the manual 2-1 band.
7. Install the manual 2-1 band servo piston assembly (1).
8. Install the manual valve (1) into the control valve body. (Scheme 234)
9. To aid in alignment and assembly, install tool Guide Pins (J-25025).
10. Install the control valve body gasket (6). (Scheme 239)
11. Install the control valve body assembly (5). Attach the manual valve to the detent lever while installing the control valve body assembly.
12. Install the transmission fluid pressure manual valve position switch (2).
13. Install the transmission fluid pressure manual valve position switch bolts (1) finger tight.
14. Tighten the bolts in the order shown. (Scheme 240) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000).
15. Remove the guide pins.
16. Install the manual shaft detent roller and spring assembly (3) and bolts. (Scheme 233)
17. Install the two wiring harness clips (1) and bolts (2).
18. Install the wiring harness clip (1) and bolts (2).
19. Install the lube oil pipe (5) with the short end into the control valve body.
20. Install the lube oil pipe retainer (7) and bolt (6).
21. Install the control valve body bolts. Tighten the bolts in the order shown. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000).
22. Install the remaining control valve body bolts. Tighten the remaining bolts specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000).
23. Connect the internal wiring harness to the valve body electrical components.
24. Install the oil pan, gasket and filter. See «DRAINING & REFILLING»(ref-156344-S39127061732003071400000) under LUBRICATION.
25. Lower the vehicle.
26. Fill the transmission to the proper level with appropriate transmission fluid. See «RECOMMENDED FLUIDS»(ref-156344-S36195301832003071400000) and «FLUID CAPACITIES»(ref-156344-S00062355512003071400000) under LUBRICATION.

Scheme 239

Scheme 240

Raise and support the vehicle. Place a drain pan under the vehicle. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove the output shaft seal (3) from the extension housing (4) using the slide hammer adapter and the universal seal remover. (Scheme 241) Inspect the case extension housing for damage. Replace the extension housing if necessary.

Scheme 241

Lubricate the inside diameter of the new seal with assembly lubricant. Use the rear lubricant seal installer with a soft faced mallet to install the seal (2). (Scheme 242) Install the seal (2) to the extension housing (3). Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. Remove the drain pan and lower the vehicle. Fill transmission with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

Scheme 242

1. Remove the engine air cleaner. Remove the transmission fluid level indicator from the fluid fill tube. Remove the engine cover. Remove the bolt and the nut securing the transmission fluid fill tube to the engine.
2. Remove the nut securing the transmission fluid fill tube to the transmission stud. (Scheme 243) Remove the upper fill tube from the vehicle. Raise and support the vehicle.
3. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. Remove the drain plug from the transmission. Drain the fluid into an approved container. Remove the transmission fluid fill tube from the transmission. Pull the tube upward from the transmission.
4. Remove the transmission fill tube seal. Clean the metal parts using solvent. DO NOT allow the solvent to enter the transmission. Air dry the parts.

Scheme 243

1. Install a NEW oil level indicator tube seal into the transmission case. Install the bottom of oil level indicator tube into the seal. (Scheme 243) Remove the safety stands. Lower the vehicle.
2. Install the upper fill tube to the vehicle. Install the bolt and the nut securing the oil level indicator tube brackets to the engine. Tighten the bolt and nut to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000).
3. Install the nut securing the oil level indicator tube to the transmission stud and tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000). On all models, install the air cleaner.
4. Install the oil level indicator. Install air cleaner. Install engine cover. Adjust fluid level as necessary. See «RECOMMENDED FLUIDS»(ref-156344-S36195301832003071400000) and «FLUID CAPACITIES»(ref-156344-S00062355512003071400000) under LUBRICATION.

1. Raise and support the vehicle. Remove the oil pan and filter. See «DRAINING & REFILLING»(ref-156344-S39127061732003071400000) under LUBRICATION.
2. Remove the 6 forward servo cover bolts, cover and gasket.
3. Remove the following parts: Forward servo piston pin (5). (Scheme 244) "O" ring seal (4). Servo piston (3). Retainer (2). Piston spring (1).

Scheme 244

1. Install the following parts: Piston spring (1). (Scheme 244) Retainer (2). Servo piston (3). O-ring seal (4). Forward servo piston pin (5).
2. Install the 6 forward servo gasket, cover and 6 bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000).
3. Install the oil pan and filter. See «DRAINING & REFILLING»(ref-156344-S39127061732003071400000) under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-156344-S36195301832003071400000) and «FLUID CAPACITIES»(ref-156344-S00062355512003071400000) under LUBRICATION.

1. Raise the vehicle. Support the vehicle with safety stands. Remove the 2 oil cooler lines from the radiator. (Scheme 245) If equipped with the auxiliary transmission oil cooler, remove the outlet pipe from the auxiliary cooler pipe.
2. Remove the 2 oil cooler lines from the transmission. Remove the 2 oil cooler lines from the clips on the frame rail. NOTE: Perform the following procedures when removing the retaining ring and cooler line from the quick connect fitting on the transmission.
3. Pull the plastic cap back from the quick connect fitting and down along the cooler line about two inches. (Scheme 247) 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.
4. Remove the retaining ring from the quick connect fitting. (Scheme 246) Discard the retaining ring. Pull the cooler line straight out from the quick connect fitting.
5. Remove the retaining ring (E-clips) securing the cooler line to the quick connect in order to remove the remaining cooler lines from the remaining quick connect fittings. Remove the cooler lines from the vehicle. Lower the vehicle.

Scheme 245

Scheme 246

Scheme 247

1. Raise the vehicle. Install the transmission oil cooler line to the vehicle. NOTE: 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.
2. Install the new retaining ring (E-clip) into the quick connect fitting. Install the 2 cooler lines to the radiator. If equipped with the auxiliary oil cooler, install the inlet line to the radiator and the outlet to the auxiliary cooler line. Install the 2 oil cooler lines to the transmission.
3. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 248) Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. (Scheme 249) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. (Scheme 250)
4. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. (Scheme 251) Install the new retaining ring (E-clip) into the remaining quick connect fittings. NOTE: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation.
5. 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 252)
6. DO NOT use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 253) Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
7. 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. Ensure that the plastic cap is fully seated against the fitting. (Scheme 254) Ensure that no gap is present between the cap and the fitting. (Scheme 255)
8. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. DO NOT install the cooler line into the fitting incorrectly. (Scheme 256)
9. If you cannot position the plastic cap against the fitting, remove the retaining ring from the quick connect fitting per step 3 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 1 of the cooler line installation procedure. Install the cooler line into the quick connect fitting again in order to install the remaining cooler lines into the remaining quick connect fittings.
10. Install the engine or transmission cooler lines to the frame. Lower the vehicle.

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

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 257)
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 257

1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats. (Scheme 258) 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 258) 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-156344-S10541896052003071400000).
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-156344-S10541896052003071400000).
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 258

1. Raise the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(ref-156344-S39127061732003071400000) under LUBRICATION. WARNING: Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal injury could result.
2. Remove the reverse boost valve bushing retainer ring (2). (Scheme 259)
3. Remove the following from the reverse boost valve cylinder: Reverse boost valve bushing. (Scheme 260) Reverse boost valve. Pressure regulator spring retainer. Pressure regulator spring. Pressure regulator valve. Reverse boost valve bushing.

Scheme 259

Scheme 260

1. Install the pressure regulator valve with Transjel(R) Lubricant (J-36850).
2. Pre-assemble the following parts: Reverse boost valve bushing. (Scheme 260) NEW reverse boost valve. NEW pressure regulator spring retainer. Added isolator pressure regulator spring. Pressure regulator spring.
3. Install the pre-assembled parts into the pump bore.
4. Install the reverse boost valve bushing retainer ring while holding the reverse boost valve bushing in place. Ensure the retainer ring (2) is in the groove. (Scheme 259)
5. Install the transmission oil pan and the oil filter. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-156344-S36195301832003071400000) and «FLUID CAPACITIES»(ref-156344-S00062355512003071400000) under LUBRICATION.

Remove the transmission oil pan and filter. See DRAINING & REFILLING under LUBRICATION. Remove the rear servo assembly from the transmission case as follows

1. Cover bolts (6). (Scheme 261)
2. Cover (5).
3. Cover gasket (4).
4. Bottom retaining clip (3).
5. Servo piston (2).
6. Outer ring oil seal (1).
7. Inner ring oil seal (7).
8. Accumulator piston (8).
9. Piston seal (9).
10. Washer (10).
11. Servo spring (11).
12. Servo spring retainer (12).
13. Selective pin (13).
14. Accumulator spring (14).

Scheme 261

1. Install the rear servo assembly into the transmission case as follows: Accumulator spring (14). Selective pin (13). Servo spring retainer (12). Servo spring (11). Washer (10). Piston seal (9). Accumulator piston (8). Inner ring oil seal (7). Outer ring oil seal (1). Servo piston (2). Bottom retaining clip (3). Cover gasket (4). Cover (5). Cover Bolt (6).
2. Install the cover bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-156344-S10541896052003071400000) .
3. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-156344-S39127061732003071400000) under LUBRICATION. Lower vehicle. Fill transmission with appropriate fluid to proper level. See «RECOMMENDED FLUIDS»(ref-156344-S36195301832003071400000) and «FLUID CAPACITIES»(ref-156344-S00062355512003071400000) under LUBRICATION.

1. Apply the parking brake. Position the steering column shift lever to Park. Remove the knee bolster trim panel. Remove the knee bolster bracket.
2. Remove the clip securing the shift cable to the steering column bracket. Remove the shift cable from the steering column shift control. Remove the rubber grommet from the floor panel. Remove the air cleaner assembly.
3. Remove the shift cable clips from the left front of the engine compartment. Raise the vehicle. Remove the shift cable clips from the left rear engine bracket. see scheme 7
4. Remove the shift cable from the stud ball. Remove the locking clip from the cable at the bracket. Lower the vehicle. Remove the shift 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.
2. Remove the black shipping tab from the transmission end of the shift cable and discard the tab. Install the ball stud on the transmission.
3. 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.
4. Install the shift cable clips to the engine brackets. Lower the vehicle. NOTE: Ensure the shift lever is in the Park position.
5. 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. Adjust the shift cable. See «SHIFT CABLE»(ref-156344-S22226795312003071400000) under ADJUSTMENTS. Install the knee bolster bracket. Install the knee bolster trim panel.

Raise and support the vehicle. Remove the oil pan and the filter. See DRAINING & REFILLING under LUBRICATION. Remove the valve bore plug retainer ring. (Scheme 262) Remove the plug. Remove the valve. Remove the spring.

Scheme 262

Install the spring, the valve and the plug. (Scheme 262) Install the valve bore plug retainer ring. Install the filter and the oil pan. See DRAINING & REFILLING under LUBRICATION. Lower the vehicle. Fill transmission with appropriate fluid to proper level. See RECOMMENDED FLUIDS and FLUID CAPACITIES under LUBRICATION.

Disconnect the speed sensor connectors (2). Remove the vehicle speed sensor bolts. Remove the vehicle speed sensors (1) and the bracket assemblies from the case. (Scheme 263) Inspect the vehicle speed sensor assemblies (1) for any evidence of damage.

Scheme 263

Lubricate the input speed sensor seal with automatic transmission fluid. Install the vehicle speed sensors (1) and the bracket assemblies on the case. (Scheme 263) Install the bolts and tighten to specification. See TORQUE SPECIFICATIONS. Connect the speed sensor connectors (2). Lower the vehicle.