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Automatic Transmission - 4L60-E/4L65-E - Introduction: Removal & Installation Hummer H2 I

Automatic Trans 3 illustrations ~10615 words

Removal Procedure

  1. Loosen the set screw (1).
  2. Pull up to remove the shift control knob (2) from the transmission control assembly.

Installation Procedure

  1. Install the shift control knob (2) to the transmission shift control assembly.
  2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the shift knob set screw. Tighten: Tighten the shift control knob set screw (1) to 2 N.m (18 lb in).
  1. Position the shift lever to the park position.
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  3. Ensure the transmission manual shaft is positioned to mechanical park.
  4. Remove the range selector retaining clip and then the cable from the bracket at the transmission.
  5. Remove the range selector cable end (2) from the transmission range selector lever ball stud (1).
  6. Lower the vehicle and ensure that the shift lever is still in the park position.
  7. Remove the console. Refer to «Console Replacement»(ref-187217-S27783040252005083100000) in Instrument Panel, Gauges and Console.
  8. Remove the cable end (1) from the floor shift control assembly ball stud.
  9. Remove the range selector cable (2) from the floor shift control assembly.
  10. Remove the grommet on the shift cable from the floor panel.
  11. Remove the range selector cable from the vehicle.
  1. Route the cable through the hole in the floor panel.
  2. Ensure that the steering column shift lever is in the park position.
  3. Install the cable grommet to the floor panel.
  4. Install the cable end (1) to the floor shift control assembly ball stud.
  5. Install the console. Refer to «Console Replacement»(ref-187217-S27783040252005083100000) in Instrument Panel, Gauges and Console.
  6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  7. Ensure that the transmission manual shaft lever is in the mechanical park position.
  8. Install the range selector cable into the bracket at the transmission.
  9. Install the cable retaining clip.
  10. Install the range selector cable end (2) to the transmission range selector lever ball stud (1).
  11. Lower the vehicle.
  1. Apply the parking brake.
  2. Shift the transmission into neutral.
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  4. Disconnect the transmission range selector cable from the shift lever and the bracket (2). Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187261-S41819625822005083100000) .
  5. Remove the bolts (1) securing the transmission range selector cable bracket (2) to the transmission.
  6. Remove the transmission range selector cable bracket from the vehicle.
  1. Install the transmission range selector cable bracket to the vehicle.
  2. Install the transmission range selector cable bracket bolts (1). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  3. Install the transmission range selector cable to the bracket (2) and the lever. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187261-S41819625822005083100000) .
  4. Lower the vehicle.
  5. Check the vehicle for proper operation. If adjustment of the cable is necessary, refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-187261-S05244886862005083100000) .
  1. Remove the front floor console. Refer to «Console Replacement»(ref-187217-S27783040252005083100000) in Instrument Panel, Gauges and Console.
  2. Remove the end of the range selector cable (1) from the transmission control ball stud.
  3. Remove the range selector cable (2) from the floor shift control.
  4. Remove the transmission control bolts.
  5. Remove the transmission control.
  1. Install the transmission control.
  2. Install the transmission control bolts. Tighten: Tighten the transmission control bolts to 25 N.m (18 lb ft).
  3. Install the range selector cable (2) to the floor shift control.
  4. Install the end of the range selector cable (1) to the transmission control ball stud.
  5. Install the front floor console. Refer to «Console Replacement»(ref-187217-S27783040252005083100000) in Instrument Panel, Gauges and Console.
  6. Check for proper operation of the floor shift control.
  7. Adjust the range selector cable if necessary. Refer to «Automatic Transmission Range Selector Cable Adjustment»(ref-187261-S05244886862005083100000) .
  1. Apply the parking brake.
  2. Shift the transmission into neutral.
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  4. Remove the nut securing the transmission control lever to the manual shaft.
  5. Remove the transmission control lever from the manual shaft.
  6. Disconnect the electrical connectors from the switch.
  7. Remove the bolts securing the park/neutral position switch to the transmission.
  8. Remove the park/neutral position switch from the manual shaft. If the park/neutral position switch did not slide off the manual shaft, file the outer edge of the manual shaft in order to remove any burrs.
  1. Install the switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats.
  2. Slide the switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission.
  3. Install the switch to the transmission with two bolts finger tight.
  4. Position the 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.
  5. Rotate the tool until the upper locator pin on the tool is lined up with the slot on the top of the switch. Tighten: Tighten the bolts securing the switch to 25 N.m (18 lb ft).
  6. Remove the J 41364-A from the switch. If installing a new switch, remove the positive assurance bracket at this time.
  7. Connect the electrical connectors to the switch.
  8. Install the transmission control lever to the manual shaft with the nut. Tighten: Tighten the control lever nut to 25 N.m (18 lb ft).
  9. Lower the vehicle.
  10. Check the switch for proper operation. The engine must start in the P (Park) or N (Neutral) positions only. If proper operation of the switch can not be obtained, replace the switch.
  1. Remove the instrument panel trim plate bezel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-187217-S32969193842005083100000) in Instrument Panel, Gauges, and Console.
  2. Remove the switch recepticle screws.
  3. Pull the switch recepticle from the instrument panel and disconnect the electrical connectors from the switch.
  4. Remove the switch from the recepticle.
  1. Install the switch to the recepticle.
  2. Connect the electrical connector to the switch. Install the switch recepticle to the instrument panel.
  3. Install the switch recepticle screws. Tighten: Tighten the screws to 12 N.m (106 lb in).
  4. Install the instrument panel trim plate bezel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(ref-187217-S32969193842005083100000) in Instrument Panel, Gauges, and Console.
CAUTIONWhen the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Place a drain pan under the transmission oil pan.
  3. Remove the oil pan drain plug, if equipped.
  4. If necessary, remove the bolts and position aside the range selector cable bracket for clearance while lowering the pan. It is not necessary to remove the cable from the lever or bracket.
  5. Remove the oil pan bolts from the front and sides of the pan only.
  6. Loosen the rear oil pan bolts approximately 4 turns.
  7. Lightly tap the oil pan with a rubber mallet in order to loosen the pan to allow the fluid to drain.
  8. Remove the remaining oil pan bolts.
  9. Remove the oil pan and the gasket.
  10. Grasp firmly while pulling down with a twisting motion in order to remove the filter.
  11. Remove the filter seal. The filter seal may be stuck in the pump; if necessary, carefully use pliers or another suitable tool to remove the seal.
  12. Discard the seal.
  13. Inspect the fluid color.
  14. Inspect the filter. Pry the metal crimping away from the top of the filter and pull apart. The filter may contain the following evidence for root cause diagnosis: Clutch material Bronze slivers indicating bushing wear Steel particles
  15. Clean the transmission case and the oil pan gasket surfaces with solvent, and air dry. You must remove all traces of the old gasket material.
  1. Coat the new filter seal with automatic transmission fluid.
  2. Install the new filter seal into the transmission case. Tap the seal into place using a suitable size socket.
  3. Install the new filter into the case.
  4. Install the oil pan and a new gasket.
  5. Install the oil pan bolts. Tighten: Tighten the oil pan to transmission case bolts alternately and evenly to 11 N.m (97 lb in).
  6. If previously removed, install the range selector cable bracket and bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  7. Apply a small amount of sealant GM P/N 12346004, (Canadian P/N 10953480) to the threads of the oil pan drain plug, if equipped.
  8. Install the oil pan drain plug, if equipped. Tighten: Tighten the oil pan drain plug to 18 N.m (13 lb ft).
  9. Lower the vehicle.
  10. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) and «Fluid Capacity Specifications»(ref-187261-S37866356042005083100000) .
  11. Check the COLD fluid level reading for initial fill only.
  12. Inspect the oil pan gasket for leaks.
  1. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) in Engine Controls - 6.0L.
  2. Remove the transmission fluid cooler hoses from the transmission fluid Auxiliary cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  3. Remove the bolts from the auxiliary oil cooler.
  4. Remove the auxiliary oil cooler from the vehicle.
  5. Remove the transmission fluid cooler hose from the auxiliary transmission fluid cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  6. Remove the transmission fluid cooler hoses from the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  8. Remove the bolts from the transmission fluid cooler hose insulator.
  9. Remove the transmission fluid cooler hose insulator from the transmission.
  10. Remove the cooling lines from the clips.
  11. Remove the transmission fluid cooler hoses from the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  1. Install the transmission fluid cooler hoses to the transmission. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  2. Install the cooling lines to the clips.
  3. Install the transmission fluid cooler hose insulator to the transmission.
  4. Install the bolts to the transmission fluid cooler hose insulator. Tighten: Tighten the bolts to 17 N.m (12 lb ft).
  5. Lower the vehicle.
  6. Install the transmission fluid cooler hoses to the radiator. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  7. Install the transmission fluid cooler hose to the auxiliary transmission fluid cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  8. Install the auxiliary oil cooler to the vehicle.
  9. Install the bolts to the transmission fluid auxiliary cooler. Tighten: Tighten the bolts to 17 N.m (12 lb ft).
  10. Install the transmission fluid cooler hoses to the transmission fluid Auxiliary cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  11. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-187222-S15189587742005083100000) in Engine Controls - 6.0L.
  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-187259-S24384045282005083100000) .
  1. Remove the transmission fluid cooler hoses from the transmission fluid auxiliary cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  2. Remove the bolts from the auxiliary oil cooler.
  3. Remove the auxiliary oil cooler from the vehicle.
  1. Install the auxiliary oil cooler to the vehicle.
  2. Install the bolts to the transmission fluid auxiliary cooler. Tighten: Tighten the bolts to 12 N.m (9 lb ft).
  3. Install the transmission fluid cooler hoses to the transmission fluid auxiliary cooler. Refer to «Transmission Fluid Cooler Line Quick Connect Fitting»(ref-187261-S41537210232005083100000) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General information.
  2. Drain the transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) in Automatic Transmission - 4L60-E/4L65-E.
  3. Remove the right hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
  4. Remove the heat shield bolts and heat shield from the transmission.
  5. Install the J 29714-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  6. Tighten the bolt in order to compress the servo cover.
  7. Remove the servo cover retaining ring.
  8. Remove the J 29714-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  9. Remove the servo cover and the 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.
  10. Remove the 2-4 servo from the transmission.
  11. Inspect the 4th apply piston, 2-4 servo converter, 2nd apply piston, and the servo piston inner housing for the following defects. Cracks Scoring Burrs and nicks
  1. Install new seals on the servo pistons and the servo cover.
  2. Install the 2-4 servo assembly into the transmission.
  3. Install the J 29714-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Tighten the bolt in order to compress the servo cover.
  5. Install the servo cover retaining ring.
  6. Remove the J 29714-A from the oil pan flange. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  7. Install the oil pan bolt. Tighten: Tighten the oil pan bolt to 11 N.m (97 lb in).
  8. Install the heat shield.
  9. Install the two bolts securing the transmission heat shield to the transmission. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  10. Install the right hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
  11. Lower the vehicle.
  12. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  3. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring.
  4. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
  5. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4).
  6. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
  7. Remove the pressure regulator valve (1).
  1. Install the pressure regulator valve (1).
  2. Install the pressure regulator isolator spring (3) and the pressure regulator valve spring (2).
  3. Install the reverse boost valve (4) in the reverse boost valve sleeve (5).
  4. Install the reverse boost valve (4) and sleeve (5) in the oil pump cover.
  5. Compress the reverse boost valve sleeve into the bore of the oil pump to expose the retaining ring slot.
  6. Install the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
  7. Install the transmission oil filter and pan. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  8. Lower the vehicle.
  9. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Remove the transmission oil level indicator.
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  3. Remove the right hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
  4. Remove the transmission heat shield bolt and shield.
  5. Remove the nut securing the oil lever indicator tube to the transmission housing.
  6. Place a drain pan under the vehicle.
  7. Remove the oil level indicator tube from the transmission case and seal.
  8. Remove the seal from the transmission case.
  1. Install a new seal into the transmission case.
  2. Install the oil level indicator tube into the seal.
  3. Install the nut securing the oil level indicator tube to the transmission stud. Tighten: Tighten the nut to 18 N.m (13 lb ft).
  4. Install the transmission heat shield.
  5. Install the 2 bolts retaining the heat shield. Tighten: Tighten the bolts to 17 N.m (13 lb ft).
  6. Install the right hand catalytic converter. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
  7. Lower the vehicle.
  8. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the Park/Neutral Position (PNP) Switch. Refer to «Park/Neutral Position Switch Replacement»(ref-187261-S30509012002005083100000) .
  3. Be sure that the jackscrew for J 43911 is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Rotate the removal tool so that the threads on the end of the tool engage the steel shell (1) of the seal. Use a wrench to be sure that the removal tool is firmly attached to the seal shell.
  5. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed.
  1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. Position the seal so that it is starting to enter the seal bore.
  2. Obtain J 43909 and remove the inner sleeve so that the tool will slide over the selector shaft. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Slide the J 43909 into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 and drive the new seal into the seal bore until it is seated at the bottom of the bore. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Install the PNP Switch. Refer to «Park/Neutral Position Switch Replacement»(ref-187261-S30509012002005083100000) .
  5. Lower the vehicle.
  6. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Ensure that removal of the valve body is necessary before proceeding. IMPORTANT: The following components can be serviced without removing the valve body from the transmission: The torque converter clutch solenoid (1) The pressure control solenoid (2) The internal wiring harness (3) The 2-3 shift solenoid (4) The 1-2 shift solenoid (5) The transmission fluid pressure manual valve position switch (6) The 3-2 shift solenoid (7) The torque converter clutch pulse width modulation (TCC PWM) solenoid (8)
  2. Remove the fluid level indicator.
  3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  4. Remove the oil pan, gasket, and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  5. Disconnect the internal wiring harness electrical connectors from the following components: The transmission fluid pressure manual valve position switch (1) The 1-2 shift solenoid (2) The 2-3 shift solenoid (3) The pressure control solenoid (4) The TCC PWM solenoid (5) The 3-2 shift solenoid (6)
  6. Remove the fluid indicator stop bracket bolt (2).
  7. Remove the fluid indicator bracket (1).
  8. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible.
  9. Remove the TCC PWM solenoid (1) in order to access the TCC solenoid retaining bolts.
  10. Remove the TCC solenoid retaining bolts.
  11. Remove the TCC solenoid (with O-ring seal) and wiring harness from the control valve body.
  12. Reposition the harness to the side of the transmission case.
  13. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body.
  14. Remove the transmission fluid pressure switch.
  15. Inspect the transmission fluid pressure switch for damage or debris.
  16. Remove the manual detent spring retaining bolt.
  17. Remove the manual detent spring.
  18. Inspect the manual detent spring for cracks or damage.
  19. Remove the remaining control valve body bolts.
  20. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link.
  1. Install the checkballs (1-7) in the valve body.
  2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve.
  3. Verify that the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2).
  4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place.
  5. Do not install the transmission fluid indicator stop bracket and bolt at this time. Install but do not tighten the control valve body bolts which retain only the valve body directly. Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: M6 X 1.0 X 65.0 (1) M6 X 1.0 X 54.4 (2) M6 X 1.0 X 47.5 (3) M6 X 1.0 X 35.0 (4) M8 X 1.0 X 20.0 (5) M6 X 1.0 X 12.0 (6) M6 X 1.0 X 18.0 (7)
  6. Install the manual detent spring.
  7. Install but do not tighten the manual detent spring retaining bolt.
  8. Install the transmission fluid pressure switch.
  9. Install but do not tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body.
  10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. Tighten: Tighten the control valve body bolts (in sequence) to 11 N.m (97 lb in).
  11. Ensure that the manual detent spring is aligned properly with the detent lever. Tighten: Tighten the manual detent spring bolt to 11 N.m (97 lb in).
  12. Install the TCC solenoid with a new O-ring seal to the valve body.
  13. Install the TCC solenoid bolts. Tighten: Tighten the TCC solenoid retaining bolts to 11 N.m (97 lb in).
  14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit.
  15. Place the tab between the valve body and the pressure switch in the location shown (2). Press the harness into position on the valve body bolt bosses (1, 3).
  16. Install the TCC PWM solenoid (1) to the control valve body.
  17. Install the TCC PWM solenoid retainer (2).
  18. Install the transmission fluid indicator stop bracket (1) and bolt (2). Tighten: Tighten the transmission fluid indicator stop bracket bolt to 11 N.m (97 lb in).
  19. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch (1) The 1-2 shift solenoid (2) The 2-3 shift solenoid (3) The pressure control solenoid (4) The TCC PWM solenoid (5) The 3-2 shift solenoid (6)
  20. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  21. Lower the vehicle.
  22. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Remove the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  2. Remove the 1-2 accumulator if necessary. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187261-S03647323812005083100000) .
  3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) TCC PWM solenoid (5) 3-2 control solenoid (6)
  4. Remove the pressure control solenoid retainer.
  5. Remove the pressure control solenoid.
  6. Remove the 1-2 and 2-3 shift solenoid retainers.
  7. Remove the 1-2 and 2-3 shift solenoids.
  8. Remove the 3-2 control solenoid retainer.
  9. Remove the 3-2 control solenoid.
  1. Install the 3-2 control solenoid.
  2. Install the 3-2 control solenoid retainer.
  3. Install the 1-2 and 2-3 shift solenoids.
  4. Install the 1-2 and 2-3 shift solenoid retainers.
  5. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard.
  6. Install the pressure control solenoid retainer and retaining bolt. Tighten: Tighten the pressure control solenoid retaining bolt to 11 N.m (97 lb in).
  7. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) TCC PWM solenoid (5) 3-2 control solenoid (6)
  8. Install the 1-2 accumulator. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187261-S03647323812005083100000) .
  9. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  10. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the transmission oil pan and the filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  3. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. Depress both tabs on the connector and pull straight up; do not pry the connector.
  4. Remove the 1-2 accumulator assembly. Do not remove the spacer plate. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187261-S03647323812005083100000) .
  5. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) TCC PWM solenoid (5) 3-2 control solenoid (6)
  6. Remove the TCC PWM solenoid retainer.
  7. Remove the TCC PWM solenoid in order to access one of the TCC solenoid retaining bolts.
  8. Remove the pressure control solenoid retainer.
  9. Remove the pressure control solenoid.
  10. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness.
  11. Using J 28458 , release the pass-through electrical connector from the transmission case. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) . Use the small end of the J 28458 over the top of the connector. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) . Twist in order to release the four tabs retaining the connector. Pull the harness connector down through the transmission case.
  12. Remove the TCC solenoid (with O-ring seal) and wiring harness assembly from the transmission case.
  13. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage Cracked connectors Exposed wires Loose pins
  1. Install the wiring harness and TCC solenoid assembly with a new O-ring seal to the transmission.
  2. Install the pass-through electrical connector to the transmission case.
  3. Install the valve body bolts which retain the internal wiring harness and install the TCC solenoid retaining bolts. Tighten: Tighten the control valve body retaining bolts to 11 N.m (97 lb in). Tighten the TCC solenoid retaining bolts to 11 N.m (97 lb in).
  4. Install the pressure control solenoid. Ensure that the electrical tabs are facing outboard.
  5. Install the pressure control solenoid retainer and retaining bolt. Tighten: Tighten the pressure control solenoid retaining bolt to 11 N.m (97 lb in).
  6. Install the TCC PWM solenoid to the control valve body.
  7. Install the TCC PWM solenoid retainer.
  8. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch (1) 1-2 shift control solenoid (2) 2-3 shift control solenoid (3) Pressure control solenoid (4) TCC PWM solenoid (5) 3-2 control solenoid (6)
  9. Install the 1-2 accumulator. Refer to «Accumulator Assembly, Spacer Plate, and Gaskets»(ref-187261-S03647323812005083100000) .
  10. 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.
  11. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  12. Lower the vehicle.
  13. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  3. Remove the control valve body. Refer to «Valve Body and Pressure Switch Replacement»(ref-187261-S23280709022005083100000) .
  4. Remove the accumulator cover retaining bolts.
  5. Remove the 1-2 accumulator cover assembly.
  6. Disassemble the 1-2 accumulator. Blow compressed air into the 1-2 accumulator cover, as shown, to remove the 1-2 accumulator piston. Remove the 1-2 accumulator inner and outer springs.
  7. Inspect the 1-2 accumulator inner and outer springs for cracks.
  8. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston.
  9. Inspect the 1-2 accumulator piston for the following defects: Porosity Cracks Scoring Nicks and scratches
  10. Inspect the 1-2 accumulator cover for the following defects: Porosity Cracks Scoring Nicks and scratches
  11. Remove the spacer plate support retaining bolts.
  12. Remove the spacer plate support.
  13. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket.
  14. Remove the 3-4 accumulator piston (2).
  15. Inspect the 3-4 accumulator spring for cracks.
  16. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston.
  17. Inspect the 3-4 accumulator piston for the following defects: Porosity Cracks Scoring Nicks and scratches
  1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston.
  2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with J 36850 .
  3. Install the 3-4 accumulator piston (2) onto the pin (1) in the transmission case. Ensure that the 3-4 accumulator piston legs face away from the transmission case.
  4. Install the J 25025-B (2, 3) to the transmission case. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use J 36850 in order to retain the 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, 2) are in place on the spacer plate.
  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. Tighten: Tighten the spacer plate support retaining bolts to 11 N.m (97 lb in).
  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.
  12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston.
  13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover.
  14. Install the 1-2 accumulator piston onto the pin in the 1-2 accumulator cover. Ensure that the piston legs face the accumulator cover.
  15. Install the 1-2 accumulator cover and the accumulator cover retaining bolts. Tighten: Tighten the accumulator cover retaining bolts to 11 N.m (97 lb in).
  16. Remove the J 25025-B from the transmission case. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  17. Install the control valve body. Refer to «Valve Body and Pressure Switch Replacement»(ref-187261-S23280709022005083100000) .
  18. Install the transmission oil pan and filter. Refer to «Automatic Transmission Fluid/Filter Replacement»(ref-187261-S40041072282005083100000) .
  19. Lower the vehicle.
  20. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .
  1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the electrical connector from the speed sensor.
  3. Remove the speed sensor and the O-ring from the transfer case.
  1. Install the new rear speed sensor into the transfer case with a new O-ring seal. Tighten: Tighten the right rear speed sensor to 17 N.m (13 lb ft).
  2. Install the electrical connector to the speed sensor.
  3. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  2. Remove the catalytic converter guard. Refer to «Catalytic Converter Guard Replacement»(ref-187245-S04691823662005083100000) .
  3. Support the transmission with a transmission jack.
  4. Remove the two nuts securing the transmission mount to the transmission support.
  5. Raise the transmission off of the transmission support.
  6. Remove the bolts.
  1. Install the transmission mount to the vehicle.
  2. Install the bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
  3. Lower the transmission and install the two nuts securing the transmission mount to the transmission support. Tighten: Tighten the nuts to 40 N.m (30 lb ft).
  4. Remove the transmission jack.
  5. Install the catalytic converter guard. Refer to «Catalytic Converter Guard Replacement»(ref-187245-S04691823662005083100000) .
  6. Lower the vehicle.
  1. Disconnect the battery.
  2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-187252-S32674187102005083100000) in General Information.
  3. Support the transmission with a transmission jack.
  4. Remove the exhaust pipe assembly. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
  5. Remove the starter motor. Refer to «Starter Motor Replacement»(ref-187208-S22382514562005083100000) in Engine Electrical.
  6. Lower the transmission to gain access to the top and sides of the transmission.
  7. Remove the transfer case. Refer to «Transfer Case Assembly Replacement»(ref-187236-S38719831422005083100000) .
  8. Remove the shift cable end from the transmission shift lever ball stud and the pan rail bracket. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187261-S41819625822005083100000) .
  9. Remove the transmission heat shield.
  10. Disconnect the transmission vent hose, the park/neutral position switch connector, and the main electrical connector from the transmission. Refer to «Park/Neutral Position Switch Replacement»(ref-187261-S30509012002005083100000) .
  11. Remove the bolt that secures the fuel line bracket to the left side of the transmission.
  12. Remove the torque converter access plug.
  13. Remove the flywheel to torque converter bolts.
  14. Disconnect the transmission oil cooler lines from the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-187261-S35828658512005083100000) .
  15. Plug the transmission oil cooler line connectors in the transmission case.
  16. Remove the transmission fill tube retaining nut from the transmission stud.
  17. Remove the engine harness bracket retaining nuts from the transmission studs.
  18. Remove the fill tube from the transmission.
  19. Remove the engine harness brackets from the transmission studs and position aside.
  20. Remove the bolts securing the transmission to the engine oil pan.
  21. Remove the six studs and one bolt securing the transmission to the engine.
  22. Pull the transmission straight back.
  23. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.
  24. Perform the automatic transmission oil cooler flushing and flow test. Refer to «Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096)»(ref-187259-S09202454942005083100000) or «Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A)»(ref-187259-S34783554832005083100000) .
  1. Support the transmission with a transmission jack.
  2. Raise the transmission into place.
  3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand.
  4. Install six studs and one bolt securing the transmission to the engine. Tighten: Tighten the studs and the bolt to 50 N.m (37 lb ft).
  5. Install the bolts securing the transmission to the engine oil pan. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  6. Install the engine harness bracket onto the appropriate transmission studs.
  7. Install the fill tube onto the transmission.
  8. Instal the engine harness bracket and fill tube nuts onto the transmission studs. Tighten: Tighten the nuts to 18 N.m (13 lb ft).
  9. Install the flywheel to torque converter bolts. Tighten: Tighten the bolts to 63 N.m (46 lb ft).
  10. Install the torque converter access plug.
  11. Connect the cooler lines to the transmission. Refer to «Transmission Fluid Cooler Hose/Pipe Replacement»(ref-187261-S35828658512005083100000) .
  12. Install the transmission vent hose, fuel lines, and the wiring harness connectors to the transmission and park neutral switch.
  13. Install the two bolts securing the heat shield to the transmission. Tighten: Tighten the bolt to 17 N.m (13 lb ft).
  14. Install the shift cable to the shift lever ball stud and the bracket. Refer to «Automatic Transmission Range Selector Cable Replacement»(ref-187261-S41819625822005083100000) .
  15. Install the transfer case. Refer to «Transfer Case Assembly Replacement»(ref-187236-S38719831422005083100000) in Transfer Case - BW 4484.
  16. Install the starter motor. Refer to «Starter Motor Replacement»(ref-187208-S22382514562005083100000) in Engine Electrical.
  17. Install the exhaust pipe assembly. Refer to «Catalytic Converter Replacement (Right Hand)»(ref-187284-S33119295632005083100000) in Engine Exhaust.
  18. Flush the transmission oil cooler and cooling lines if necessary.
  19. Lower the vehicle.
  20. Connect the battery.
  21. Fill the transmission to the proper level with DEXRON® III transmission fluid. Refer to «Transmission Fluid Checking Procedure»(ref-187259-S24384045282005083100000) .

Pan and Filter Assembly Removal

  1. Remove the transmission oil pan screws (76).
  2. Remove the transmission oil pan (75) and the transmission oil pan gasket (73).
  3. Remove the transmission oil filter assembly (72).
  4. The filter may help in diagnosis. Cut away the top portion of the plastic filter housing and remove. Inspect the filter for the presence of the following items which may indicate wear or corrosion: Clutch material Bronze slivers indicating bushing wear Steel particles
  5. Remove the oil filter seal (71).

Valve Body and Wiring Harness Removal

  1. Remove all electrical connectors (1-6) from the electrical components.
  2. Remove the TCC PWM retainer clip (395).
  3. Remove the TCC PWM solenoid (396).
  4. Remove the TCC solenoid bolts (68).
  5. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so that it hangs over the side of the transmission.
  6. Remove the transmission fluid pressure (TFP) manual valve position switch assembly bolts (62, 70).
  7. Remove the TFP manual valve position switch (69).
  8. Remove the manual detent spring bolt (64).
  9. Remove the manual detent spring assembly (63).
  10. Remove all valve body bolts (62).
  11. Remove the fluid level indicator stop bracket (93).
  12. Lift the valve body carefully so that the checkballs remain on the spacer plate in the correct location. While lifting the valve body, disconnect the manual valve link from the manual valve.
  13. Remove the seven valve body checkballs (2-6, 8, 12).
  14. Remove the accumulator cover bolts (58, 59).
  15. Remove the 1-2 accumulator cover and pin assembly (57).
  16. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104).
  17. Remove the spacer plate support bolts (77).
  18. Remove the spacer plate support (53).
  19. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard gaskets. Do not reuse.
  20. Remove the 3-4 accumulator spring (model dependent) and the 3-4 accumulator piston.
  21. Remove the case checkball (#1).

Scheme 195

Scheme 195: Turbine Shaft O-Ring Removal
Scheme 195: Turbine Shaft O-Ring Removal

Remove the O-ring (618) from the turbine shaft. O-Ring location is model dependent.

Oil Pump Removal

Tools Required

  1. J 37789-A Oil Pump Remover/Installer. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 39119 Oil Pump Remover/Installer Adapter. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Remove all pump bolts (2).
  2. Install J 39119 over stator shaft until it locks under splines. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Install J 37789-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. To prevent slipping, securely fasten the J 37789-A around the J 39119 by tightening the bolt (1) with a wrench. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  5. Turn the T-handle on top of J 37789-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  6. Lift the pump out of the case.
  7. Remove the pump cover to case gasket (6).

2-4 Band, Input Clutches, Input Gear Set Removal

  1. Remove the band anchor pin.
  2. Remove the input housing and shaft assembly and the reverse input clutch housing and drum assembly.
  3. Remove the 2-4 band assembly (602).

Reaction Gear Set Removal

  1. Use snap ring pliers remove the output shaft to input carrier retainer (661).
  2. Remove the input carrier assembly (662) and remove the bearing assembly (663).
  3. Remove the input internal gear (664) and the reaction carrier shaft assembly (666).
  4. Remove the thrust washer (669a or 669b) and the reaction sun shell (670).

Inner Manual Linkage Removal

  1. Remove the following parts: Hex head nut (90) Manual valve link (89) Detent lever (88) Parking lock actuator assembly (85) Manual shaft retainer (83) Manual shaft (84)
  2. Remove the manual shaft seal (82) with a screwdriver.
  3. Remove the following components: The parking lock bracket bolt (87) The parking lock bracket (86)

Low and Reverse Clutch Piston Removal

Tools Required

  1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 34627 Snap Ring Remover and Installer. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. J 42628 Disc. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Install the J 23327-1 and the J 42628 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Tighten the J 23327-1 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Remove the low and reverse clutch retainer ring (693) using the J 34627 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Remove the low and reverse clutch spring assembly (694).
  5. Blow compressed air into the case passage to remove the low and reverse clutch piston (695). (1) LO Feed Passage (2) REV Feed Passage

Third Accumulator Retainer and Ball Replacement

  1. Remove the third accumulator retainer and ball assembly, using a 6.3 mm (0.25 in) #4 screw extractor.
  2. Scribe a mark at 42 mm (1.653 in) on a 9.5 mm (0.375 in) diameter metal rod. The scribe mark is used to gauge the proper depth of the third accumulator retainer and ball assembly.
  3. Perform the following functions: Line up the oil feed slots in the third accumulator retainer and ball assembly (40) with the servo bore. Using the 9.5 mm (0.375 in) diameter metal rod, install the third accumulator retainer and ball assembly.
  4. Ensure that the third accumulator retainer and ball assembly and the scribe mark on the rod are flush with the case surface.
  5. Check the third accumulator retainer and ball assembly (40) for alignment. The slot in the retainer must be completely open in the servo bore.

Scheme 196

Scheme 196: Manual Shaft Seal Installation
Scheme 196: Manual Shaft Seal Installation

Install a new manual shaft seal (82).

Low and Reverse Clutch Piston Installation

Tools Required

  1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 34627 Snap Ring Remover and Installer. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. J 36850 Transjel Lubricant
  1. Install the transmission (low and reverse clutch outer, center, inner) seals (696) on the low and reverse clutch piston (695).
  2. Lubricate the seals with assembly lubricant J 36850 or an equivalent.
  3. Install the low and reverse clutch piston (695) into the case. The notch in the piston must be aligned with the parking brake pawl window, in the case.
  4. Install the low and reverse clutch spring assembly (694). Using the J 23327-1 , compress the low and reverse clutch spring assembly (694). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) . Using J 36850 install the low and reverse clutch retainer ring (693).

Inner Manual Linkage Installation

  1. Install the parking lock bracket (86).
  2. Install the parking lock bracket bolt (87). Tighten: Tighten the bolt to 31 N.m (23 lb ft).
  3. Inspect the following items: The parking brake pawl (81) for damage or cracks The parking pawl return spring (80) for being broken or missing
  4. Inspect the following items: The manual shaft retainer (83) for damage or cracks The manual shaft (84) for damage or burrs The parking lock actuator assembly (85) for damage The inside detent lever (88) for damage or cracks The manual valve link (89) for damage The hex head nut (90) for damage or stripped threads
  5. Install the following items: The inside detent lever (88) The parking lock actuator assembly (85) The manual shaft (84) (model dependent) The manual shaft retainer (83) The hex head nut (90) The manual valve link (89) Tighten: Tighten the nut to 31 N.m (23 lb ft).

Low and Reverse Clutch Plates Installation

  1. Install the waved plate.
  2. Install the correct selective spacer plate (from the selection procedure).
  3. Install the five fiber plate assemblies and four steel plates, starting with one fiber plate assembly and alternating with steel.
  4. Index the steel plate splines in the case as shown.

Low and Reverse Clutch Support Installation

  1. Install the low and reverse roller clutch race (675). Simultaneously, turn and insert the race.
  2. Rotate the race in order to verify proper operation. The race should only rotate in one direction.
  3. Install the low and reverse clutch support retainer spring (680) into the case.
  4. Install the low and reverse clutch support (679), roller clutch and roller clutch race (675) assembly into the case. Position the hub side down during the installation.
  5. Install the low and reverse support retainer ring (676) into the case.

Reaction Sun Gear Installation

Tools Required

  1. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 8092 Universal Driver Handle - 3/4 in
  1. Inspect the reaction sun gear (673) for the following defects: Nicks Scores Damaged spline or teeth A worn bushing (672) A loose or weak retaining ring (671)
  2. If the reaction sun gear bushing (672) needs replacement, use J 34196-1 which is part of kit J 34196-B with J 8092 to remove the reaction sun bushing (672) from the reaction sun gear (673). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Using J 34196-1 which is part of kit J 34196-B with J 8092 , install a new reaction sun bushing (672) into the reaction sun gear (673). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Install the reaction sun gear (673) into the reaction carrier.
  5. Install the thrust washer (674) with the tangs pointing down. Index the tangs of the thrust washer with the splines of the low and reverse roller clutch race.

Tools Required

  1. J 8092 Universal Driver Handle - 3/4 in - 10
  2. J 7004-A Universal Remover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. J 23907 Slide Hammer with Bearing Adapter
  4. J 25019-14 Stator Pump Bushing Remover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  5. J 29369-2 Bushing and Bearing Remover 2-3 in
  6. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Remove the reaction carrier shaft/internal gear retainer (668) and the reaction carrier shaft (666) from the input internal gear (664).
  2. Inspect the reaction carrier shaft (666) and the input internal gear (664) for the following defects: Scoring Cracking Damaged or worn bushings A cracked shaft A damaged spline Damaged gear teeth
  3. Using J 29369-2 with J 23907 , remove the reaction carrier shaft front bushing (665).
  4. Using J 25019-14 with J 7004-A , remove the reaction carrier shaft rear bushing (667). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Using J 34196-3 which is part of kit J 34196-B with J 8092 , install a new reaction carrier shaft front bushing (665). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Using J 34196-3 which is part of kit J 34196-B with J 8092 , install a reaction carrier shaft rear bushing (667). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Tools Required

  1. J 8433 Two Jaw Puller
  2. J 21427-A Speedometer Gear Puller Adapter. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. J 36352 Speed Sensor Rotor Installer Kit. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Inspect the internal transmission speed sensor rotor (699) for cracks or damaged teeth.
  2. Inspect all splines on the output shaft (687) for cracks or damaged splines.
  3. Remove the output shaft seal (691) and the output shaft sleeve (690) (model dependent) 2WD units only.
  4. If the internal speed sensor rotor (699) is damaged, replace it.
  5. Using J 8433 with J 21427-01 , remove the internal speed sensor rotor (699) from the output shaft (687).
  1. Slip a new internal speed sensor rotor (699) over the output shaft splines.
  2. Install the J 36352-4 in the groove on the output shaft (687). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Place the J 36352-6 on the output shaft (687). Press on the J 36352-6 until it contacts the J 36352-4 in the window (the J 36352-4 will be a positive stop for the J 36352-6 ). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Tools Required

  1. J 8092 Universal Driver Handle - 3/4 in - 10
  2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Scheme 197

Scheme 197
Scheme 197

Using J 34196-5 which is part of kit J 34196-B with J 8092 , remove the input sun gear front bushing (657) and rear bushing (659). See Special Tools and Equipment .

  1. Using J 34196-4 which is part of kit J 34196-B with J 8092 , install the input sun gear front bushing (657). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Using J 34196-6 which is part of kit J 34196-B with J 8092 , install the input sun gear rear bushing (659). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Tools Required

  1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 23456 Booster and Clutch Pack Compressor. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Remove the reverse input clutch housing and drum assembly (605) from the input clutch assembly (621).
  2. Remove the stator shaft/selective washer bearing assembly (615).
  3. Remove the selective thrust washer (616).
  4. Remove the 3rd and 4th clutch backing plate retainer ring (656).
  5. Remove all 3rd and 4th clutch plates (653-655).
  6. Remove the 3-4 clutch boost spring assemblies (600).
  7. Remove the forward clutch backing plate retainer ring (651).
  8. Remove the forward clutch selective backing plate (650).
  9. Remove the forward clutch sprag assembly.
  10. Remove all forward clutch plates (646, 648, 649A, 649B).
  11. Remove the input sun gear bearing assembly (637).
  12. Remove the input housing to output shaft seal (636).
  13. Remove all overrun clutch plates (645A, 645B).
  14. Install the J 23327-1 and the J 25018-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  15. Compress the overrun clutch spring, using the J 23456 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  16. Remove the overrun clutch spring retainer snap ring (635).
  17. Remove the J 23327-1 and the J 25018-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  18. Remove the overrun clutch spring assembly (634).
  19. Remove the overrun clutch piston (632).
  20. Remove the forward clutch piston (630).
  21. Remove the forward clutch housing (628).
  22. Remove the 3rd and 4th clutch spring assembly (626).
  23. Remove the 3rd and 4th clutch apply ring (625).
  24. Remove the 3rd and 4th clutch piston (623).

Overrun Clutch Installation

  1. Inspect the fiber plate assemblies (645B) and the steel plates (645A) for the following defects: Damaged tangs Delamination Excessive wear Wear or heat damage
  2. Install the overrun clutch plates into the input housing starting with a steel plate (645B) and alternating with fiber plate assemblies (645A).
  3. Index the plates in the input housing with the wide notches remaining open.
  4. Install the input sun gear bearing assembly (637) into the input housing.

Turbine Shaft Seals Installation

Tools Required

  1. J 36418-1B Turbine Shaft Seal Installer. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 36418-2A Turbine Shaft Seal Sizer. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Use the J 36418-1B in order to install the four turbine shaft oil seal rings (619). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Place the J 36418-2A over the turbine shaft oil seal rings (619). Leave the J 36418-2A on the shaft until the reverse input clutch must be installed on the input clutch. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Tools Required

  1. J 25019 Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. J 7004-A Universal Remover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. J 8092 Universal Driver Handle - 3/4 in - 10
  1. Inspect the reverse input clutch housing and drum assembly for the following conditions: Damaged or worn bushings Surface finish on the hub and outer housing - check band surface for flatness Leak at the weld Heat distortion Rolled or distorted retaining ring groove
  2. Using the J 25019-16 with the J 7004-A , remove the reverse input clutch front bushing (603). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Using the J 25019-4 with the J 8092 , remove the reverse input clutch rear bushing (606). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Using the J 25019-9 with the J 8092 , install a reverse input clutch front bushing (603). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Using the J 34196-3 which is part of kit J 34196-B with the J 8092 , install a reverse input clutch rear bushing (606). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Reverse Input and Input Clutches Installation

  1. Install the selective thrust washer (616) on the input housing (621).
  2. Install the stator shaft/selective washer bearing assembly (615) on the input housing (621). The black race on the bearing goes toward the oil pump.
  3. Install the reverse input clutch assembly (605) on the input housing (621).
  4. Index the reverse input clutch plates with the input clutch hub. Make certain all clutch plates are fully engaged.
  5. Install the reverse input and the input clutch assembly into the transmission case.
  6. Index the 3rd and 4th clutch plates with the input internal gear. Ensure that all clutch plates are fully engaged. When properly assembled, the reverse input clutch housing will be located just below the case oil pump face.

2-4 Band Assembly Installation

  1. Inspect the 2-4 band assembly (602) for damage or wear.
  2. Install the 2-4 band (602) into the case.
  3. Install the band anchor pin into the case.
  4. Index the band to fit the band anchor pin into the band.

Tools Required

  1. J 41778-1 Pump Body Bushing Installer/Remover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 41778-2 Pump Body Bushing Position Stop. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Inspect the oil pump body for the following defects: Worn or damaged bushings Foreign material or debris Porosity Scored or irregular mating faces Cross channel leaks Ring groove damage
  2. Remove the front helix retainer (244).
  3. Remove the oil seal assembly (243).
  4. Using the J 41778-1 with an arbor press, remove the pump body bushing (242). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  5. Using J 41778-1 with an arbor press, install a new pump body bushing (242). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  6. Use the J 41778-2 to ensure proper bushing depth. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Tools Required

  1. J 7004-A Universal Remover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 8092 Universal Driver Handle - 3/4 in - 10
  3. J 21465-01 Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Inspect the pump cover, all check valve retainer and ball assemblies (237), cup plugs (235, 236) and orificed cup plugs (238, 240).
  2. Inspect the pump cover for the following: Worn or damaged bushings Foreign material or debris Porosity Scored or irregular mating faces Cross channel leaks Ring groove damage
  3. Using the J 21465-15 with the J 7004-A , remove the stator shaft front bushing (234). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Using the J 25019-14 with the J 7004-A , remove the stator shaft rear bushing (241). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Using the J 21465-2 and the J 8092 , install a new stator shaft front bushing (234).See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Using the J 34196-2 which is part of kit J 34196-B and the J 8092 , install the stator shaft rear bushing (241). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .

Oil Pump Assembly Installation

Tools Required

  1. J 25025-1 Dial Indicator Mounting Post. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 39855 Stator Shaft Seal Installer. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Install the J 25025-1 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. Remove the J 39855-2 which is part of kit J 39855 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Install the pump to drum thrust washer (601).
  4. Use J 36850 or equivalent to retain the washer to the pump.
  5. Install the oil pump to case seal (5) on the oil pump assembly (4).
  6. Install the pump cover to case gasket (6).
  7. Install the oil pump assembly (4) into the case and align all holes properly.
  8. Install the pump to case bolts (2) with new O-ring seals (3). Tighten: Tighten the bolts to 29 N.m (21 lb ft).
  9. Remove the J 25025-1 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  10. Install the remaining pump to case bolts (2) and O-ring seals (3), in the holes where the J 25025-1 were. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) . Tighten: Tighten the bolts to 29 N.m (21 lb ft).

Turbine Shaft O-Ring Installation

Install the O-ring (618) on the turbine shaft. O-Ring location is location dependent.

  1. Install the following items: The isolator valve (398) The regulator apply spring (397) The regulator apply valve (380) The bore plug (381) The bore plug retainer (395)
  2. Install the following items: The 4-3 sequence valve spring (382) The 4-3 sequence valve (383) The 3-4 relay valve (384) The bore plug (381) The bore plug retainer (395)
  3. Install the following items: The 3-4 shift valve (385) The 3-4 shift valve spring (386) The bore plug (381) The bore plug retainer (395)
  4. Install the following items: The reverse abuse valve (387) The reverse abuse valve spring (388) The bore plug (359) The coiled spring pin (360) The 3-2 downshift valve (389) The 3-2 downshift valve spring (390) The bore plug (381) The bore plug retainer (395)
  5. Install the following items: The 3-2 control valve spring (392) The 3-2 control valve (391) The 3-2 control solenoid (394) The solenoid retainer (395)
  6. Install the following items: The actuator feed limit valve (374) The actuator feed limit valve spring (375) The bore plug (376) The bore plug retainer (395) The pressure control solenoid (377) 1 - Colorado/Canyon 2 - All other models The solenoid retainer (378) NOTE: Refer to «Fastener Notice»(ref-187216-S26822158702005083100000) in Cautions and Notices. The solenoid retainer bolt (364) Tighten: Tighten the bolt to 8-14 N.m (6-10 lb ft).
  7. Install the following items: The 1-2 accumulator valve spring (370) The 1-2 accumulator valve (371) in the 1-2 accumulator valve sleeve (372) The 1-2 accumulator valve and sleeve assembly The coiled spring pin (360)
  8. Install the following items: The 2-3 shift valve (368) The 2-3 shuttle valve (369) The 2-3 shift solenoid valve (367B) The solenoid retainer (395)
  9. Install the following items: The 1-2 shift valve spring (365) The 1-2 shift valve (366) The 1-2 shift solenoid valve (367A) The solenoid valve retainer (395)
  10. Install the following items: The forward abuse valve (357) The forward abuse valve spring (358) The bore plug (359) The coiled spring pin (360) The low overrun valve (361) The low overrun valve spring (362)
  11. Install the following items: The forward accumulator oil seal (353) on the forward accumulator piston (354) The forward accumulator pin (355) The forward accumulator piston (354) The forward accumulator spring (356) The forward accumulator cover (363) The forward accumulator cover bolts (364)
  12. Install the manual valve (340).

3-4 Accumulator Installation

  1. Inspect the 3-4 accumulator piston (44) for the following conditions: Porosity Cracks Scoring Nicks and scratches
  2. Install the 3-4 accumulator piston oil seal ring (45) on the 3-4 accumulator piston (44).
  3. Install the 3-4 accumulator piston (44) and seal assembly into the bore.
  4. Inspect the 3-4 accumulator spring (46) for cracks.
  5. Install the 3-4 accumulator spring.

1-2 Accumulator Installation

Tools Required

  1. J 25025-5 Dial Indicator Mounting Post - M6. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 36850 Transjel Lubricant
  1. Inspect the valve body spacer plate and the solenoid screens (49, 50) for damage or debris. Replace the solenoid screens (49, 50) if necessary.
  2. Install the #1 checkball into the case.
  3. Install the J 25025-5 into the case. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  4. Place the spacer plate to case gasket (47) (identified by a "C") and the spacer plate to valve body gasket (52) (identified by a "V") on the spacer plate (48). Retain gaskets on the spacer plate with J 36850 or equivalent.
  5. Place the spacer and the spacer plate gaskets on the case.
  6. Install the spacer plate support plate (53).
  7. Install the spacer plate support bolts (77).
  8. Install the 1-2 accumulator housing assembly (57).
  9. Install the 1-2 accumulator housing bolts (58, 59). Tighten: Tighten the bolts to 11 N.m (8 lb ft).

Control Valve Body Installation

Tools Required

  1. J 25025-5 Dial Indicator Mounting Post M6 x 1. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .00
  2. J 36850 Transjel Lubricant
  1. Install the checkballs (2-6, 8, 12) in the valve body and retain checkballs with J 36850 or an equivalent.
  2. Install the valve body over the J 25025-5 Guide Pins, and connect the manual valve link to the manual valve. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  3. Install two bolts to hold the valve body in place.
  4. Remove the J 25025-5 . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  5. Install the fluid level indicator stop bracket (93) and the valve body bolts (62) that are shown only.
  6. Finger tighten the bolts.
  7. Inspect the Transmission Fluid Pressure (TFP) Manual Valve Position Switch Assembly for the following conditions: Damage Debris Damaged or missing O-rings Cracked connector Loose pins Poor terminal retension Sediment in switch membrane
  8. Install the TFP manual valve position switch (69) and bolts (62, 70).
  9. Inspect the wiring harness solenoid assembly for the following conditions: Damage Cracked connectors Exposed wires Loose pins Poor terminal retension
  10. Install the transmission wiring harness on the valve body.
  11. Install the TCC solenoid valve and bolts (68).
  12. Tighten the bolts in the order shown. Tighten: Tighten the bolts to 11 N.m (8 lb ft). Each bolt number refers to a specific bolt size, as indicated by the following list: 1 - M6 x 1.0 x 65.0 2 - M6 x 1.0 x 54.4 3 - M6 x 1.0 x 47.5 4 - M6 x 1.0 x 35.0 5 - M8 x 1.25 x 20.0 6 - M6 x 1.0 x 12.0 7 - M6 x 1.0 x 18.0
  13. Install the TCC PWM solenoid valve (396) and the solenoid retainer (395).
  14. Connect all electrical connectors (1-6) to the electrical components.

Manual Detent Spring Installation

  1. Inspect the manual detent spring assembly (63) for cracks or damage.
  2. Install the manual detent spring assembly (63).
  3. Install the manual detent spring bolt (64). Tighten: Tighten the bolt to 20-27 N.m (15-20 lb ft).

Oil Filter Assembly Installation

  1. Lubricate the filter seal (71) with transmission fluid.
  2. Use a socket the same size diameter as the filter seal (71) and install the seal.
  3. Install the transmission oil filter assembly (72).

Transmission Oil Pan Installation

  1. Place the transmission oil pan gasket (73) on the case.
  2. Place the transmission oil pan (75) on the case.
  3. Install all of the transmission oil pan screws (76). Tighten: Tighten the screws to 16 N.m (11.8 lb ft).

2-4 Servo Assembly Installation

Tools Required

  1. J 22269-01 Accumulator and Servo Piston Remover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  2. J 29714-A Servo Cover Depressor. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  1. Inspect the 4th apply piston (25), the 2-4 servo cover (28), the 2nd apply piston (17), and the servo piston inner housing (20) for the following conditions: Cracks Scoring Burrs and nicks
  2. Install the following seals: The 4th apply piston outer oil seal ring (26) on the 4th apply piston (25). The 2-4 servo cover O-ring seal (27) on the 2-4 servo cover (28). The 2nd apply piston outer (18) and inner (19) oil seal rings on the 2nd apply piston (17). The O-ring seal (21) on the servo piston inner housing (20).
  3. Install the servo cushion outer spring (16), the servo cushion inner spring (105) (model dependent) and the cushion spring retainer (15) in the 2nd apply piston (17).
  4. Use the J 22269-01 and compress the second apply piston assembly (17). See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  5. Install the second apply piston retaining ring (14).
  6. Assemble the 2-4 servo components in the order shown: (12-15, 17, 20, 22-25, 28, 29).
  7. Install the 2-4 servo assembly into the 2-4 servo bore.
  8. Install the J 29714-A . See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  9. Tighten the bolt on the J 29714-A in order to compress the servo cover. See «Special Tools and Equipment»(ref-187261-S18358459572005083100000) .
  10. Install the servo cover retaining ring.

More articles — Automatic Transmission - 4L60-E/4L65-E - Introduction