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

REMOVAL & INSTALLATION

Removal

1. Remove the control valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-161097-S19455080772004031700000).
2. Remove the accumulator cover bolts. (Scheme 3)
3. Remove the 1-2 accumulator cover.
4. Disassemble the 1-2 accumulator as follows: Blow compressed air into the 1-2 accumulator cover in order to remove the 1-2 accumulator piston. (Scheme 4) Remove the 1-2 accumulator inner and outer springs.
5. Inspect the 1-2 accumulator inner and outer springs for cracks.
6. Remove the 1-2 accumulator piston seal (1) from the 1-2 accumulator piston. (Scheme 5)
7. Inspect the 1-2 accumulator piston for the following defects: Porosity. Cracks. Scoring. Nicks and scratches.
8. Inspect the 1-2 accumulator cover for the following defects: Porosity. Cracks. Scoring. Nicks and scratches. (Scheme 6)
9. Remove the spacer plate support bolts. (Scheme 7) NOTE: Use care not to drop the number one checkball, the 3-4 accumulator spring and the 3-4 accumulator pin.
10. Remove the spacer plate support.
11. Remove the spacer plate to valve body gasket, the spacer plate and the spacer plate to transmission case gasket. (Scheme 8)
12. Remove the 3-4 accumulator piston. (Scheme 9)
13. Inspect the 3-4 accumulator spring for cracks.
14. Remove the 3-4 accumulator piston seal (1) from the 3-4 accumulator piston. (Scheme 5)
15. Inspect the 3-4 accumulator piston for the following defects: Porosity. Cracks. Scoring. Nicks and scratches.

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Installation

1. Install a new 3-4 accumulator piston seal (1) to the 3-4 accumulator piston. (Scheme 5)
2. Install the 3-4 accumulator pin (1) into the transmission case and retain the pin with Transjel(R) lubricant. (Scheme 10)
3. Install the 3-4 accumulator piston onto the pin in the transmission case. (Scheme 9) Ensure that the 3-4 accumulator piston legs face away from the transmission case.
4. Install the pump and valve body alignment pin set (2, 3) to the transmission case. (Scheme 10)
5. Install the spacer plate to transmission case gasket and the spacer plate to valve body gasket to the spacer plate; use Transjel(R) lubricant in order to retain the gaskets to the spacer plate. (Scheme 11) The case gasket is identified by a "C". Be sure to place the case gasket on the transmission case side of the spacer plate. The valve body gasket is identified by a "V". Be sure to place the valve body gasket on the valve body side of the spacer plate.
6. Ensure that the solenoid screens (1 and 2) are in place on the spacer plate.
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 bolts. (Scheme 7) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
11. After installing the spacer plate support (2), look through the hole in the spacer plate to ensure that the checkball (1) has remained in the proper location. (Scheme 12)
12. Install a new 1-2 accumulator piston seal (1) to the 1-2 accumulator piston. (Scheme 5)
13. Install the 1-2 accumulator inner and outer springs to the 1-2 accumulator cover. (Scheme 13)
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 bolts. (Scheme 3) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
16. Remove the pump and valve body alignment pin set from the transmission case.
17. Install the valve body. See «VALVE BODY & PRESSURE SWITCH»(ref-161097-S19455080772004031700000).
18. Install the transmission filter.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. Open hood. Remove the transmission fluid cooler hoses from the transmission fluid auxiliary cooler. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .
2. Remove the bolts from the auxiliary transmission oil cooler. Remove the auxiliary transmission oil cooler from the vehicle.

1. Install the auxiliary transmission oil cooler to the vehicle.
2. Install the bolts to the auxiliary transmission oil cooler. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) .
3. Connect the transmission oil cooler lines to the auxiliary cooler. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .

1. Loosen shift control knob set screw. Pull up to remove the shift control knob (2) from the transmission control assembly.
2. Remove the screws that hold center console storage bin in place. Remove the storage bin from the center console.
3. Using a flat bladed tool, pry up on the cup holder to release the clips. Disconnect the PRNDL lamps from the cup holder. Remove the cup holder.
4. Remove screws that hold end panel to center console. Disconnect electrical connectors to end panel. (Scheme 14) Remove console end panel.
5. Pull upwards on the upper console trim panel to release the trim panel clips. (Scheme 15) Remove the upper console trim panel.
6. Disconnect the console electrical connector. Remove the bolts holding center console to center console bracket. Remove the center console.

Scheme 14

Scheme 15

Note. Make sure HVAC duct is aligned with center console.

1. Align center console to center console bracket and route the electrical wiring through console. Connect the console electrical connector.
2. Install the center console to center console bracket. Install the center console bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
3. Align the upper trim panel with center console. (Scheme 15) Push towards the console to engage the trim panel clips.
4. Connect electrical connectors to console end panel. (Scheme 14) Install the center console end panel. Install the center console end panel screws. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
5. Connect the lamps to the cup holder. Align the cup holder to the center console. Push the cup holder firmly into place to engage the clips.
6. Install shift handle to shifter and fasten in place. Tighten the set screw to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
7. Install the center console storage bin. Install the storage bin screws. Tighten the screws to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).

1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION. NOTE: DO NOT remove the valve body for the following procedures. Removal of the 1-2 accumulator is necessary only if servicing the pressure control solenoid.
2. Remove the 1-2 accumulator if necessary. See «ACCUMULATOR ASSEMBLY»(ref-161097-S01217735962004031700000).
3. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. (Scheme 16) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid. 3-2 shift control solenoid.
4. Remove the pressure control solenoid retainer. Remove the pressure control solenoid. (Scheme 17)
5. Remove the 1-2 and 2-3 shift control solenoid retainers. Remove the 1-2 and 2-3 shift control solenoids. (Scheme 18)
6. Remove the 3-2 control solenoid retainer. Remove the 3-2 control solenoid. (Scheme 19)

Scheme 16

Scheme 17

Scheme 18

Scheme 19

1. Install the 3-2 control solenoid. Install the 3-2 control solenoid retainer. Install the 1-2 and 2-3 shift control solenoids. (Scheme 19)
2. Install the 1-2 and 2-3 shift control solenoid retainers. Install the pressure control solenoid. Ensure the electrical tabs are facing outboard. (Scheme 18)
3. Install the pressure control solenoid retainer and retaining bolt and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
4. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. (Scheme 16) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 control solenoid.
5. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(ref-161097-S01217735962004031700000).
6. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.
7. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-161097-S33197725722004031700000).

1. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
2. Remove the transmission mount. See «TRANSMISSION MOUNT»(ref-161097-S03181232752004031700000).
3. Support the transmission with a transmission jack.
4. Place a drain pan under the vehicle.
5. Remove the case extension bolts (1). (Scheme 20)
6. Remove the case extension (2).
7. Remove and discard the case extension "O" ring seal (3).

Scheme 20

1. Install a new case extension "O" ring seal (3). (Scheme 20)
2. Install the case extension (2).
3. Install the case extension bolts (1). Tighten the case extension bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
4. Install the transmission mount. See «TRANSMISSION MOUNT»(ref-161097-S03181232752004031700000).
5. Remove the drain pan and the transmission jack.
6. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
7. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-161097-S33197725722004031700000).

1. Place a drain pan under the vehicle.
2. Remove the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
3. Remove the rear extension transmission oil seal. (Scheme 21)
4. Inspect the case extension housing for damage. Replace the extension housing if necessary.

Scheme 21

1. Lubricate the inside diameter of the NEW seal with Transjel(R) lubricant.
2. Install the new seal using rear extension seal installer and a soft faced mallet. (Scheme 22)
3. Remove the drain pan.
4. Install the drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
5. Fill transmission with appropriate fluid to proper level. See «LUBRICATION»(ref-161097-S33197725722004031700000).

Scheme 22

1. Remove the transmission oil level indicator. Raise and suitably support the vehicle.
2. Remove frame-to-engine protection shield bolts. (Scheme 23) Remove engine protection shield. Remove the catalytic converter guard mounting bolts and guard from vehicle. (Scheme 24)
3. Disconnect the connector position assurance (CPA) retainers. Disconnect the oxygen sensor electrical connectors (1, 2). (Scheme 25)
4. Remove the catalytic converter to muffler flange nuts. Remove the exhaust manifold pipe-to-catalytic converter nuts. Remove the catalytic converter.
5. Remove the transmission heat shield bolt and shield. (Scheme 26) Remove the nut securing the transmission oil lever indicator tube to the transmission housing.
6. Place a drain pan under the vehicle. Remove the transmission oil level indicator tube from the transmission case. (Scheme 27) Remove the seal from the transmission case.

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. Install a NEW seal into transmission case. (Scheme 27) Install the transmission oil level indicator tube into seal.
2. Install the transmission level indicator tube nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
3. Install transmission heat shield. Install the 2 bolts retaining the heat shield. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
4. Install right catalytic converter and nuts. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
5. Install exhaust manifold pipe-to-catalytic converter nuts. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
6. Connect oxygen sensor electrical connectors (1, 2). (Scheme 25) Connect the CPA retainers.
7. Install the catalytic converter guard. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000). Install frame-to-engine protection shield. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
8. Lower the vehicle. Install the transmission oil level indicator.
9. Fill transmission to proper level with appropriate fluid. See «LUBRICATION»(ref-161097-S33197725722004031700000).

1. Raise the vehicle. Remove the Park/Neutral Position (PNP) Switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-161097-S39957350382004031700000).
2. Be sure that the jackscrew for Selector Shaft Seal Remover is backed off and will not interfere with installation of the removal tool. Slide the seal remover tool over the selector shaft (2) with the threaded end of the tool towards the seal. (Scheme 28)
3. 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.
4. Rotate the jackscrew in the clockwise direction to remove the seal from the bore. Discard the seal that was removed.

Scheme 28

1. Carefully slide a new selector shaft seal (1) over the selector shaft (2) with the wide face of the steel case facing outward. (Scheme 28) Position the seal so that it is starting to enter the seal bore.
2. Obtain Selector Shaft Seal Installer and remove the inner sleeve so that the tool will slide over the selector shaft.
3. Slide the Seal Installer into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the Seal Installer and drive the new seal into the seal bore until it is seated at the bottom of the bore.
4. Install the PNP Switch. See «PARK/NEUTRAL POSITION SWITCH»(ref-161097-S39957350382004031700000). Lower the vehicle.
5. Fill the transmission to the proper level with transmission fluid. See «RECOMMENDED FLUIDS»(ref-161097-S25182509282004031700000) and «CHECKING FLUID LEVEL & CONDITION»(ref-161097-S14766403992004031700000).

1. Apply the Parking brake. Shift the transmission into Neutral.
2. Raise and suitably support the vehicle.
3. Remove nut securing the transmission control lever to the manual shaft. Remove transmission control lever from manual shaft.
4. Disconnect the Park/Neutral Position (PNP) switch electrical connectors.
5. Remove the PNP switch bolts.
6. Remove the PNP switch from the manual shaft. If the PNP 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 PNP switch to the transmission manual shaft by aligning the switch hub flats with the manual shaft flats.
2. Slide the PNP switch onto the transmission manual shaft until the switch mounting bracket contacts the mounting bosses on the transmission. NOTE: If a NEW PNP switch is being installed, the switch will come with a positive assurance bracket. The positive assurance bracket aligns the new switch in its proper position for installation and the use of the park neutral switch aligner will not be necessary.
3. Install the PNP switch bolts finger tight.
4. Install park/neutral position switch aligner onto the PNP switch. (Scheme 29) 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 the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
6. Remove the park/neutral position switch aligner from the switch. If installing a new switch, remove the positive assurance bracket at this time.
7. Connect the PNP switch electrical connectors.
8. Install the transmission control lever to the manual shaft with the nut. Tighten the nut to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
9. Lower the vehicle.
10. Check the switch for proper operation. The engine must start in the Park (P) or Neutral (N) positions only. If proper operation of the switch can not be obtained, replace the switch.

Scheme 29

1. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.
2. Compress the reverse boost valve sleeve into the bore of the oil pump to release tension on the reverse boost valve retaining ring. (Scheme 30)
3. Remove the reverse boost valve retaining ring, then slowly release tension on the reverse boost valve sleeve.
4. Remove the reverse boost valve sleeve (5) and the reverse boost valve (4). (Scheme 31)
5. Remove the pressure regulator isolator spring (3) and the pressure regulator valve spring (2). Remove the pressure regulator valve (1).

Scheme 30

Scheme 31

1. Install the pressure regulator valve (1). (Scheme 31)
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. (Scheme 30)
7. Install the transmission oil filter and pan. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.

1. Position the shift lever to the Park position. Raise the vehicle. NOTE: Ensure the transmission manual shaft is positioned to mechanical park.
2. Remove the shifter retaining clip and then the cable from the bracket at the transmission. Remove the shift cable end (2) from the transmission shift lever ball stud (1). (Scheme 32)
3. Lower the vehicle and ensure that the shifter lever is still in the park position.
4. Remove center console. See «CENTER CONSOLE»(ref-161097-S14129185632004031700000).
5. Remove the cable end (1) from the floor shift control assembly ball stud. (Scheme 33) Remove the shift cable (2) from the floor shifter control assembly.
6. Remove the grommet on the shift cable from the floor panel. Remove the shift cable from the vehicle.

Scheme 32

Scheme 33

1. Route the cable through the hole in the floor panel. Ensure that the transmission shift lever is in the mechanical Park position.
2. Install the cable grommet to the floor panel. Install the shift cable end (2) to the transmission shift lever ball stud (1). (Scheme 33)
3. Install center console. See «CENTER CONSOLE»(ref-161097-S14129185632004031700000). Raise the vehicle.
4. Ensure that the transmission manual shaft lever is in the mechanical park position. Install the range selector cable into the bracket at the transmission.
5. Install the cable retaining clip. Install the range selector cable end (2) to the transmission shift lever ball stud (1). (Scheme 32) Lower the vehicle.

1. Apply the Parking brake. Place the transmission into Neutral. Raise and support the vehicle.
2. Disconnect the transmission range selector cable from the shift lever and the bracket (2). (Scheme 34)and «SHIFT CABLE»(ref-161097-S01220126052004031700000).
3. Remove the bolts (1) securing the transmission shift cable bracket (2) to the transmission. Remove the transmission shift cable bracket from vehicle.

Scheme 34

1. Install the shift cable bracket to the vehicle.
2. Install the shift cable bracket bolts (1). (Scheme 34) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
3. Install the transmission range selector cable to the bracket (2) and the lever. See «SHIFT CABLE»(ref-161097-S01220126052004031700000).
4. Lower the vehicle. Check the vehicle for proper operation. If cable adjustment is necessary, see «SHIFT CABLE»(ref-161097-S09694463102004031700000) under ADJUSTMENTS.

1. Raise and support the vehicle. Remove the transmission oil pan and the filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.
2. Disconnect the transmission harness 20-way connector from the transmission internal harness pass-through connector. (Scheme 35) Depress both tabs on the connector and pull straight up, DO NOT pry the connector.
3. Remove the 1-2 accumulator assembly. See «ACCUMULATOR ASSEMBLY»(ref-161097-S01217735962004031700000).
4. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure switch. (Scheme 16) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
5. Remove the TCC PWM solenoid retainer. (Scheme 36)
6. Remove the TCC PWM solenoid to access one of the TCC solenoid retaining bolts.
7. Remove the pressure control solenoid retainer.
8. Remove the pressure control solenoid. (Scheme 17)
9. Remove the TCC solenoid retaining bolts and the valve body bolts which retain the internal wiring harness. (Scheme 37)
10. Using the seal protector retainer installer, release the pass-through electrical connector from the transmission case. (Scheme 38) Use the small end of the seal protector retainer installer over the top of the connector. Twist to release the 4 tabs retaining the connector. Pull the harness connector down through the transmission case.
11. Remove the TCC solenoid (with "O" ring seal) and wiring harness.
12. Inspect the TCC solenoid and wiring harness assembly for the following defects: Damage. (Scheme 39) Cracked connectors. Exposed wires. Loose pins.

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Install the wiring harness and TCC solenoid assembly with a new "O" ring seal to the transmission. (Scheme 38)
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. (Scheme 37) Tighten the control valve body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000). Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
4. Install the pressure control solenoid. (Scheme 17) Ensure the electrical tabs are facing outboard.
5. Install the pressure control solenoid retainer and retaining bolt. Tighten the pressure control solenoid retaining bolt to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
6. Install the TCC PWM solenoid to the control valve body. (Scheme 36)
7. Install the TCC PWM solenoid retainer.
8. Connect the internal wiring harness electrical connectors to the following components: Transmission fluid pressure switch. (Scheme 16) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
9. Install the 1-2 accumulator. See «ACCUMULATOR ASSEMBLY»(ref-161097-S01217735962004031700000).
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. (Scheme 35)
11. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.

1. Remove the air cleaner resonator outlet duct. Remove the transmission fluid cooler hose from the auxiliary transmission oil cooler. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .
2. Remove the bolts from the auxiliary oil cooler. Remove the auxiliary oil cooler from the vehicle. Remove the transmission fluid cooler hose from the auxiliary transmission fluid cooler. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .
3. Remove the transmission fluid cooler hoses from the radiator. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) . Raise and support the vehicle.
4. Remove the bolts from the transmission fluid cooler hose insulator. Remove the transmission fluid cooler hose insulator from the transmission. Remove the cooling lines from the clips.
5. Remove the cooling lines from the transmission. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .

1. Install the cooling lines to the transmission. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .
2. Install the cooling lines to the clips. Install the transmission fluid cooler hose insulator to the transmission. Install the bolts to the transmission fluid cooler hose insulator. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) .
3. Lower the vehicle. Install the transmission fluid cooler hose to the radiator. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .
4. Install the auxiliary oil cooler to the vehicle. Install the bolts to the transmission fluid auxiliary cooler. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) .
5. Install the transmission fluid cooler hose to the Auxiliary transmission oil cooler. See «TRANSMISSION COOLER LINE QUICK CONNECT FITTING»(ref-161097-S20779303962004031700000) .
6. Install the air cleaner resonator outlet duct.

1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 2 in (5 cm).
2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. (Scheme 40)
3. Remove the retaining ring from the quick connect fitting.
4. Discard the retaining ring.
5. Pull the cooler line straight out from the quick connect fitting. (Scheme 41)

Scheme 40

Scheme 41

Note. DO NOT reuse any of the existing transmission lines or transmission line fittings if there is excessive corrosion. DO NOT reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings.

1. Install a new retaining ring into the quick connect fitting using the following procedure: Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. (Scheme 42) 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 43) DO NOT install the new retaining ring onto the fitting by pushing the retaining ring. (Scheme 44) 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 45)
2. Install the cooler line into the quick connect fitting. (Scheme 46)
3. Insert the cooler line end into the quick connect fitting until a click is either heard or felt.
4. DO NOT use the plastic cap on the cooler line in order to install the cooler line into the fitting. (Scheme 47)
5. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting.
6. Position (snap) the plastic cap onto the fitting. DO NOT manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. (Scheme 48)
7. Ensure that the plastic cap is fully seated against the fitting.
8. Ensure that no gap is present between the cap and the fitting. (Scheme 49)
9. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. (Scheme 48)
10. A hidden yellow identification band indicates proper joint seating. (Scheme 50)
11. Fill transmission to proper level with appropriate fluid. See «LUBRICATION»(ref-161097-S33197725722004031700000).

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Raise and support vehicle. Remove frame-to-engine protection shield bolts. (Scheme 23) Remove engine protection shield. Remove the catalytic converter guard mounting bolts and guard from vehicle. (Scheme 24)
2. Support the transmission with a transmission jack. Remove the two nuts securing the transmission mount to the transmission support. Raise the transmission off of the transmission support. Remove the bolts and transmission mount.

1. Install the transmission mount to the vehicle. Install the bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) .
2. Lower the transmission and install the two nuts securing the transmission mount to the transmission support. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) .
3. Remove the transmission jack. Install the catalytic converter guard. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) . Install frame-to-engine protection shield. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000) .
4. Lower the vehicle.

1. Ensure removal of the valve body is necessary before proceeding. The following components can be serviced without removing the valve body from the transmission. (Scheme 51) Torque Converter Clutch Solenoid (1) Pressure Control Solenoid (2) Internal Wiring Harness (3) 2-3 Shift Solenoid (4) 1-2 Shift Solenoid (5) Transmission Fluid Pressure Manual Valve Position Switch (6) 3-2 Shift Solenoid (7) Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid (8)
2. Remove the fluid level indicator.
3. Remove the filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.
4. Disconnect the internal wiring harness electrical connectors from the following components: Transmission fluid pressure manual valve position switch. (Scheme 16) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid. Bracket bolt.
5. Remove the fluid indicator stop bracket bolt (2). (Scheme 52) Remove the fluid indicator bracket (1).
6. Remove the TCC PWM solenoid retainer (2) with a small screwdriver. (Scheme 36) Rotate the solenoid (1) in the bore, if necessary, until the flat part of the retainer (2) is visible.
7. Remove the TCC PWM solenoid (1) to access the TCC solenoid retaining bolts. Remove the TCC solenoid bolts. (Scheme 53)
8. Remove the TCC solenoid (with "O" ring seal) and wiring harness from the control valve body.
9. Reposition the harness to the side of the transmission case. (Scheme 38)
10. Remove the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 54)
11. Remove the transmission fluid pressure switch and inspect for damage or debris. (Scheme 55)
12. Remove the manual detent spring retaining bolt. Remove the manual detent spring. (Scheme 56)
13. Inspect the manual detent spring for cracks or damage. CAUTION: Keep the control valve body level when lowering it from the vehicle. This will prevent the loss of checkballs located in the control valve body passages.
14. Remove the remaining valve body bolts.
15. Carefully begin to lower the control valve body down from the transmission case while simultaneously disconnecting the manual valve link. (Scheme 57)

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

1. Install the 7 checkballs in the valve body. (Scheme 58)
2. Install the control valve body to the transmission case while simultaneously connecting the manual valve link to the manual valve. (Scheme 57)
3. Verify the manual valve link (3) is installed properly to the inside detent lever (1) and the manual valve (2). (Scheme 59)
4. Install one bolt (M6 X 1.0 X 47.5) hand tight in the center (1) of the valve body to hold it in place. (Scheme 60) NOTE: When installing bolts throughout this procedure, be sure to use the correct bolt size and length in the correct location as specified.
5. DO NOT install the transmission fluid indicator stop bracket and bolt at this time. Install but DO NOT tighten the control valve body bolts which retain only the valve body directly. (Scheme 61) Each numbered bolt location corresponds to a specific bolt size and length, as indicated by the following: M6 X 1.0 X 65.0 (1). M6 X 1.0 X 54.4 (2). M6 X 1.0 X 47.5 (3). M6 X 1.0 X 35.0 (4). M8 X 1.0 X 20.0 (5). M6 X 1.0 X 12.0 (6). M6 X 1.0 X 18.0 (7).
6. Install the manual detent spring.
7. Install but DO NOT tighten the manual detent spring retaining bolt. (Scheme 56)
8. Install the transmission fluid pressure switch. (Scheme 54)
9. Install but DO NOT tighten the control valve body bolts which retain the transmission fluid pressure switch to the control valve body. (Scheme 54) NOTE: Torque valve body bolts in a spiral pattern starting from the center. If the bolts are torqued at random, valve bores may be distorted and inhibit valve operation.
10. Tighten the control valve body bolts in a spiral pattern starting from the center, as indicated by the arrows. (Scheme 61) Tighten the control valve body bolts (in sequence) to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
11. Ensure the manual detent spring is aligned properly with the detent lever. Tighten the manual detent spring bolt to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
12. Install the TCC solenoid with a new "O" ring seal to the valve body.
13. Install the TCC solenoid bolts. Tighten the TCC solenoid retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
14. Install the internal wiring harness to the valve body. The internal wiring harness has a tab (1) on the edge of the conduit. (Scheme 62)
15. Place the tab between the valve body and the pressure switch in the location shown (2). See. Press the harness into position on the valve body bolt bosses (1, 3). (Scheme 63)
16. Install the TCC PWM solenoid (1) to the control valve body. (Scheme 36) Install the TCC PWM solenoid retainer (2).
17. Install the transmission fluid indicator stop bracket (1) and bolt (2). (Scheme 52) Tighten the transmission fluid indicator stop bracket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
18. Connect the internal wiring harness electrical connectors to the following components: The transmission fluid pressure manual valve position switch. (Scheme 16) 1-2 shift control solenoid. 2-3 shift control solenoid. Pressure control solenoid. TCC PWM solenoid. 3-2 shift control solenoid.
19. Install the transmission oil pan and filter. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000) under LUBRICATION.

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Raise and support the vehicle.
2. Disconnect the Vehicle Speed Sensor (VSS) electrical connector. (Scheme 64)
3. Remove the VSS and "O" ring seal from transfer case.

Scheme 64

1. Install NEW VSS with a NEW "O" ring seal into the transfer case.
2. Connect the VSS electrical connector (2). (Scheme 64)
3. Lower the vehicle.
4. Refill the fluid as required. See «LUBRICATION»(ref-161097-S33197725722004031700000).

1. Raise the vehicle. Drain the transmission fluid. See «DRAINING & REFILLING»(ref-161097-S28282695782004031700000).
2. Remove frame-to-engine protection shield bolts. (Scheme 23) Remove engine protection shield. Remove the catalytic converter guard mounting bolts and guard from vehicle. (Scheme 24)
3. Disconnect the connector position assurance (CPA) retainers. Disconnect the oxygen sensor electrical connectors (1, 2). (Scheme 25)
4. Remove the catalytic converter to muffler flange nuts. Remove the exhaust manifold pipe-to-catalytic converter nuts. Remove the catalytic converter.
5. Remove the heat shield bolts. (Scheme 26) Remove the heat shield.
6. Install the servo cover depressor. (Scheme 65)
7. Tighten the bolt on servo cover depressor in order to compress the servo cover.
8. Remove the servo cover ring. (Scheme 66)
9. Remove the servo cover depressor.
10. Remove the servo cover and "O" ring seal. If the cover is hung up on the seal, use a pick (2) in order to pull and stretch the seal (1) out of the groove. Cut and remove the "O" ring seal before removing the cover. (Scheme 67)
11. Remove the 2-4 servo. (Scheme 68)
12. 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.

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. Install NEW seals onto the servo pistons and the servo cover.
2. Install the 2-4 servo. (Scheme 68)
3. Install the servo cover depressor.
4. Tighten the bolt on servo cover depressor in order to compress the servo cover. (Scheme 65)
5. Install the servo cover ring.
6. Remove the servo cover depressor.
7. Install the transmission oil pan bolt. Tighten the bolt to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
8. Install the heat shield and bolts. (Scheme 26) Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
9. Install right catalytic converter and nuts. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
10. Install exhaust manifold pipe-to-catalytic converter nuts. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
11. Connect oxygen sensor electrical connectors (1, 2). (Scheme 25) Connect the CPA retainers.
12. Install the catalytic converter guard. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000). Install frame-to-engine protection shield. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-161097-S40851412382004031700000).
13. Fill transmission to proper level with appropriate fluid. See «LUBRICATION»(ref-161097-S33197725722004031700000).