Maintenance / On Vehicle Service 4L6XE/70E 2013 PAGE 145
This manual provides Maintenance and some On-Vehicle Service Information for the 4L6XE/70E series transmission. For diagnostic information, refer to the applicable on vehicle service manual When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in place of the recommended item. All information, illustrations, and specifications in this manual are based on the latest product information available at the time of publication approval. General Motors reserves the right to make changes at any time without notice. 2013 GENERAL MOTORS. ALL RIGHTS RESERVED No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means (including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of General Motors, LLC. This applies to all text, illustrations, and tables. PAGE 146
Maintenance and On Vehicle Service Manual Model 4L6XE/4L70E Published= December, 2013 (Revised = December 2013) Always Use PAGE 147
Contents- Maintenance and On Vehicle Repair Transmission General Information... 5 How to Use This Section... 5 Basic Knowledge... 5 Arrows and Symbols... 5 Definition of Danger, Warning, Caution, and Note... 7 DANGER Defined... 7 WARNING Defined... 7 CAUTION Defined... 7 NOTE or IMPORTANT Defined... 8 Warnings... 8 Battery Disconnect Warning... 8 Brake Dust Warning... 8 Cautions... 9 Fastener Caution... 9 Transmission Maintenance Information... 10 Transmission Fluid Level and Condition Check... 10 Automatic Transmission Fluid and Filter Replacement... 13 On Vehicle Service Information... 16 Transmission Fluid Filler Tube and Seal Replacement... 16 2-4 Servo Cover Seal Replacement... 17 Manual Shift Shaft Seal Replacement... 19 Case Extension Assembly Seal Replacement... 20 Vehicle Speed Sensor O-ring Replacement... 22 Transmission Mount Replacement... 23 Propeller Shaft Main Flange Yoke Oil Seal Replacement... 24 Special Tools... 30 PAGE 148
Transmission General Information How to Use This Section This section provides the following information: General maintenance information on transmissions Procedures for on-vehicle repairs of the 4L60x/4L70E transmission When you diagnose any condition of the 4L60x/4L70E transmission, begin with a Diagnostic Starting Point. This procedure indicates the proper path of diagnosing the transmission by describing the basic checks. This procedure will then refer you to the locations of specific checks. After you have determined the cause of a condition, refer to Repair Instructions for repair procedures. Basic Knowledge Caution: Do not, under any circumstances, attempt to diagnose a powertrain condition without basic knowledge of this powertrain. If you perform diagnostic procedures without this basic knowledge, you may incorrectly diagnose the condition or damage the powertrain components. You must be familiar with some basic electronics in order to use this section of the service manual. You should also be able to use the following special tools: Arrows and Symbols A digital multimeter (DMM) A circuit tester Jumper wires or leads A line pressure gauge set This service manual uses various symbols in order to describe different service operations. PAGE 149
(1) Front of Vehicle (2) View Detail (2) View Detail (3) Ambient Air Mixed with Another Gas or Indicate Temperature Change (4) Motion or Direction (5) View Angle (6) Dimension (1:2) (7) Ambient/Clean Air Flow or Cool Air Flow (8) Lubrication Point Oil or Fluid (9) Task Related (10) Sectioning (1:3) (11) Gas Other Than Ambient Air or Hot Air Flow (12) Lubrication Point Grease or Jelly (13) Multidirectional Arrow PAGE 150
Definition of Danger, Warning, Caution, and Note The diagnosis and repair procedures in a GM Service Manual contain both general and specific Dangers, Warnings, Cautions, Notes or Importants. GM is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle; however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner. Dangers, Warnings, Cautions and Notes or Importants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring: Serious bodily injury or death to the technician Damage to the vehicle Unnecessary vehicle repairs Unnecessary component replacement Improper repair or replacement of vehicle components. Any warning or caution that appears in this service category is referenced from the individual service categories. DANGER Defined When encountering a DANGER, you will be asked to take a necessary action or not to take a prohibited action. If a DANGER is not heeded, the following consequences may occur: WARNING Defined Serious bodily injury or death to the technician Serious bodily injury or death to other technicians in the workplace area When encountering a WARNING, you will be asked to take a necessary action or not to take a prohibited action. If a WARNING is not heeded, the following consequences may occur: CAUTION Defined Serious bodily injury to the technician Serious bodily injury to other technicians in the workplace area Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired CAUTIONS call special attention to a necessary action or to a prohibited action. If a CAUTION is not heeded, the following consequences may occur: Damage to the vehicle PAGE 151
Unnecessary vehicle repairs Unnecessary component replacement Improper operation or performance of the system or component under repair Damage to any systems or components which are dependent upon the proper operation of the system or component under repair Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair Damage to fasteners, basic tools, or special tools The leakage of coolant, lubricant, or other vital fluids NOTE or IMPORTANT Defined Warnings NOTE and IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. NOTE or IMPORTANT statements are designed to do the following: Clarify a procedure Present additional information for accomplishing a procedure Give insight into the reason or reasons for performing a procedure in the manner recommended Present information that will help to accomplish a procedure in a more effective manner Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease Battery Disconnect Warning Warning: Unless directed otherwise, the ignition and start switch must be in the OFF position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. Brake Dust Warning Warning: Avoid taking the following actions when you service wheel brake parts: Do not grind brake linings. Do not sand brake linings. Do not clean wheel brake parts with a dry brush or with compressed air. PAGE 152
Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. Cautions Fastener Caution Caution: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Do not use paints, lubricants, or corrosion inhibitors on fasteners, or fastener joint surfaces, unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. When using fasteners that are threaded directly into plastic, use extreme care not to strip the mating plastic part(s). Use hand tools only, and do not use any kind of impact or power tools. Fastener should be hand tightened, fully seated, and not stripped. PAGE 153
Transmission Maintenance Information Transmission Fluid Level and Condition Check This procedure checks the transmission fluid level, as well as the condition of the fluid itself. Caution: Always use the proper automatic transmission fluid listed. Using incorrect automatic transmission fluid may damage the vehicle. Before checking the fluid level, perform the following: 1. Start the engine and park the vehicle on a level surface. Keep the engine running. 2. Apply the parking brake and place the shift lever in PARK (P). 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in ea ch range. Then, move the shift lever back to PARK (P). 4. Allow the engine to idle 500 800 RPM for at least 1 minute. Slowly release the brake pedal. 5. If the transmission fluid temperature is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate transmission fluid temperature is reached. Cold Check Procedure Note: Use the cold check procedure only as a reference to determine if the transmission has enough fluid to be operated safely until a hot check procedure can be made. The hot check procedure is the most accurate method to check the fluid level. Perform the hot check procedure at the first opportunity. o Use this cold check procedure to check fluid level when the transmission fluid temperature is between 27 32 C (80 90 F). 2. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger's side of the vehicle. 3. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. PAGE 154
4. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 5. Keep the dipstick pointing down and check both sides of the dipstick, and read the lower level. Repeat the check procedure to verify the reading. 6. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection in this procedure. 7. If the fluid level is below the COLD check line, add only enough fluid as necessary to bring the level into the COLD line. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. 8. If the fluid level is in the acceptable range, push the dipstick back in all the way, then flip the handle down to lock the dipstick in place. 9. Perform a hot check at the first opportunity after the transmission reaches a normal operating temperature between 82 93 C (180 200 F). Hot Check Procedure Note: Use this procedure to check the transmission fluid level when the transmission fluid temperature is between 82 93 C (180 200 F). The hot check procedure is the most accurate method to check the fluid level. The hot check should be performed at the first opportunity in order to verify the cold check. The fluid level rises as fluid temperature increases, so it is important to ensure the transmission temperature is within range. 1. Start the engine and locate the transmission dipstick at the rear of the engine compartment, on the passenger side of the vehicle. 2. Flip the handle up, and then pull out the dipstick and wipe the dipstick end with a clean rag or paper towel. 3. Install the dipstick by pushing it back in the dipstick tube all the way, wait three seconds and then pull it back out. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are PAGE 155
noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 4. Keep the dipstick tip pointing down and check both sides of the dipstick. Read the lower level. Repeat the check procedure to verify the reading. 5. Inspect the color of the fluid on the dipstick. Refer to Fluid Condition Inspection. 6. A safe operating fluid level is within the HOT crosshatch band on the dipstick. If the fluid level is not within the HOT band, and the transmission temperature is between 82 93 C (180 200 F), add or drain fluid as necessary to bring the level into the HOT band. If the fluid level is low, add only enough fluid to bring the level into the HOT band. 7. If the fluid level is low, add only enough fluid to bring the level into the HOT band. It does not take much fluid, generally less than one pint (0.5L). Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis. 8. If the fluid level is in the acceptable range, push the dipstick back into the dipstick tube all the way, and then flip the handle down to lock the dipstick in place. Fluid Condition Inspection Inspect the fluid color. The fluid should be red or dark brown. If the fluid color is very dark or black and has a burnt odor, inspect the fluid and inside of the bottom pan for excessive metal particles or other debris. A small amount of friction material in the bottom pan is a normal condition. If large pieces and/or metal particles are noted in the fluid or bottom pan, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid filter assembly, repair the oil cooler, and flush the cooler lines. Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. PAGE 156
Automatic Transmission Fluid and Filter Replacement Removal Procedure Warning: When the transmission is at operating temperatures, take necessary precautions when removing the drain plug, to avoid being burned by draining fluid. 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Place a drain pan under the transmission oil pan. 3. Remove the oil pan drain plug, if equipped. 4. If necessary, 8. 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 gasket. PAGE 157
10. Grasp filter 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. Installation Procedure 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. PAGE 158
4. Install the oil pan and a new gasket. Caution: Refer to Fastener Caution. 5. Install the oil pan bolts and tighten alternately and evenly to 11 N m (97 lb -in). 6. If previously removed, install the range selector cable bracket and bolts and tighten according to the vehicle manufacturer s instructions. 7. Apply a small amount of sealant GM P/N 12346004 to the threads of the oil pan drain plug, if equipped. 8. Install the oil pan drain plug, (if equipped) and tighten to 18 N m (13 lb -ft). 9. Lower the vehicle. 10. Fill the transmission to the proper level with DEXRON VI transmission fluid. Refer to Transmission Fluid Level and Condition Check and Fluid Capacity Specifications. 11. Check the COLD fluid level reading for initial fill only. 12. Inspect the oil pan gasket for leaks. PAGE 159
On Vehicle Service Information Transmission Fluid Filler Tube and Seal Replacement Removal Procedure 1. Remove the transmission fluid level indicator from the fluid fill tube. 7. Remove the transmission fill tube seal. 8. Clean the metal parts using solvent. Do not allow the solvent to enter the transmission. 2. Remove the nut securing the transmission fluid fill tube bracket to the transmission. Remove the upper transmission fill tube from the vehicle. 3. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 4. If equipped, remove the transmission pan drain plug. If no drain plug, refer to Oil Pan Removal procedure in the Automatic Transmission Fluid And Filter Replacement section. Drain the fluid into an approved container. 5. Remove any dirt from the transmission where the fluid fill tube enters the transmission case. 6. Remove the transmission fluid fill tube from the transmission. Pull the tube upward from the transmission. 9. Air dry the parts. Installation Procedure 1. Install a new oil level indicator tube seal (14) into the transmission case. 2. Install the oil level indicator tube (12) into the seal. 3. Lower the vehicle. Caution: Refer to Fastener Caution. 4. Install the nut securing the oil level indicator tube bracket to the transmission and tighten to 6 N m (53 lb in). 5. Fill the transmission to the proper fluid level. Refer to Fluid Capacity Specifications and to Transmission Fluid Level and Condition Check. PAGE 160
2-4 Servo Cover Seal Replacement Special Tools Removal Procedure 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Remove the 2 heat shield retaining bolts and the heat shield from the transmission. 3. Remove the oil pan bolt below and to the left of the 2 4 servo cover. 4. Install the J 29714-A servo cover depressor to the oil pan rail. 5. Tighten the bolt on the J 29714- A servo cover depressor in order to compress the servo cover. 6. Loosen the bolt on the J 29714- A servo cover depressor to release J 29714-A Servo Cover Depressor tension on the servo cover. 7. Loosen the bolt on the J 29714- A servo cover depressor to release tension on the servo cover. 8. Remove the servo cover and O-ring seal. If the cover is hung up on the seal, use a pick (2) to pull and stretch the seal (1) out of the groove. Cut and remove the O-ring seal before removing the cover. Installation Procedure PAGE 161
1. Install the servo cover and O-ring seal. 2. Install the J 29714-A servo cover depressor. 3. Tighten the bolt on the J 29714- A servo cover depressor in order to compress the servo cover. 4. Install the servo cover retaining ring. 5. Remove the J 29714-A servo cover depressor from the oil pan flange. Caution: Refer to Fastener Caution. 6. Install the oil pan bolt and tighten to 11 N m (97 lb in). 7. Install the 2 heat shield retaining bolts and the heat shield from the transmission then tighten to 17 N m (13 lb ft). 8. Lower the vehicle. 9. Fill the transmission to the proper level with DEXRON VI transmission fluid. PAGE 162
Manual Shift Shaft Seal Replacement Special Tools J 43911 Selector Shaft Seal Remover J 43909 Selector Shaft Seal Installer Installation Procedure Removal Procedure 1. Disconnect the range selector lever cable and lever from the manual shaft. 2. Ensure that the jackscrew for J 43911 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. 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 ensure 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. 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 selector shaft seal installer and remove the inner sleeve so that the tool will slide over the selector shaft. 3. Slide the J 43909 selector shaft seal installer into position so that the end of the tool contacts the seal being installed. Use a mallet to strike the J 43909 selector shaft seal installer and drive the new seal into the bore until it is seated at the bottom of the bore. 4. Install the shift lever nut and shift lever and tighten to 31 N m (23 lb ft). 5. Fill the transmission to the proper level with DEXRON VI transmission fluid. Refer to Transmission Fluid Level and Condition Check. PAGE 163
Case Extension Assembly Seal Replacement Removal Procedure Warning: Avoid taking the following actions when you service wheel brake parts: Do not grind brake linings. Do not sand brake linings. Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Remove transmission mount. Refer to Transmission Mount Replacement. 4. Place a drain pan under the vehicle. 5. Remove the propeller shaft. 6. Remove the two brake caliper mounting bracket bolts (2). 7. Remove caliper assembly. Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount. 8. Remove the flange yoke bolts (6), flange yoke (7), rotor (5), flange cap (4). 9. Remove the case extension bolts (2). 10. Remove the case extension (3). PAGE 164
11. Remove and discard the case extension O-ring seal (1). Installation Procedure 7. Install caliper over rotor and align caliper mounting bracket bolts with the appropriate extension housing mounting holes. 1. Install a new case extension O-ring seal (1). Caution: Refer to Fastener Caution. 2. Install the case extension (3). Rotate flange as required to align flange and output shaft splines. 3. Install the case extension bolts (2) and tighten to 45 N m (33 lb ft). 4. Install the flange cap (4), rotor (5), flange yoke (7). 5. Install flange yoke bolts (6) and tighten to 97 N m (72 lb ft). 6. Install transmission mount. Refer to Transmission Mount Replacement. 8. Install the brake caliper mounting bracket bolts (2) and tighten to 130 N m (96 lb ft). 9. Remove the drain pan and the transmission jack. 10. Install the propeller shaft 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON VI transmission fluid. Refer to Transmission Fluid Level and Condition Check. PAGE 165
Vehicle Speed Sensor O-ring Replacement Removal Procedure Installation Procedure 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Remove the electrical connector from the speed sensor. 3. Remove the bolt. 4. Remove the speed sensor and the O-ring seal. 5. Inspect the seal and the transmission case. Replace the seal, if necessary. 1. Install the speed sensor and the O-ring seal into the transmission. Caution: Refer to Fastener Caution. 2. Install the bolt and tighten to 11 N m (97 lb in). 3. Install the electrical connector to the speed sensor. 4. Lower the vehicle. PAGE 166
Transmission Mount Replacement Removal Procedure Caution: Refer to Fastener Caution. 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Remove the transmission mount to extension housing mounting bolt(s)/nut(s). 4. Remove the vehicle supporting cross member bolt(s)/nut(s). Remove the transmission mount 5. from the vehicle. Installation Procedure 1. With the transmission still supported, install the transmission mount onto the vehicle support cross member. 2. Install the transmission mount to extension housing mounting bolts, and tighten to 50 N m (37 lb ft). 3. Install the transmission mount to the support cross member bolt(s)/nut(s). 4. Tighten the transmission mount to support cross member fastener. Torque the transmission mount to vehicle cross member support nut(s)/bolt(s) to the vehicle manufacturer s recommended torque. 5. Remove the transmission jack 6. Lower the vehicle PAGE 167
Propeller Shaft Main Flange Yoke Oil Seal Replacement Tools Required J 21426 Extension Housing Seal Installer J 36850 Transjel Lubricant Removal Procedure 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Place a drain pan under the vehicle. 3. Remove the propeller shaft. Refer to your vehicle manufacturer s instructions regarding Propeller Shaft Replacement 4. Remove the Case Extension Assembly (7). Refer to Case Extension Assembly Seal Replacement. 5. Remove the speedometer reluctor wheel (4) by carefully using a gear puller to remove it from the main flange shaft. 6. Remove the main flange snap ring (5) and bearing assembly (6). 7. Remove the main flange (12) from the extension housing. 8. Remove the case extension housing rear oil seal (11). Use a flat-bladed tool and carefully pry the seal from the housing. 9. Inspect the case extension housing bushing for damage. Replace the extension bushing or housing as necessary. Installation Procedure 1. Lubricate the inside diameter of the new seal (11) with J 36850 Transjel lubricant. 2. Use the J 21426 extension housing seal installer with a soft faced mallet to install the seal. 3. Install the seal (11) to the extension housing (7). Metal PAGE 168
flange of seal should contact the extension housing. 6. Fill the transmission to the proper level with DEXRON VI transmission fluid. Refer to Transmission Fluid Level and Condition Check. 1. Lubricate the inside diameter of the case extension bushing (10) ) with J 36850 Transjel lubricant and carefully install the main flange (12) into the extension housing seal (11) and bushing (10). 2. Install the thrust bearing (6) onto the main flange shaft in the proper orientation and install the snap ring (5). 3. While supporting the main flange and extension housing assembly, carefully press the main flange speed reluctor wheel assembly (4) onto the main flange shaft until it seats against the shoulder. 4. Install the case extension assembly (7). Refer to Case Extension Assembly Seal Replacement. 5. Remove the drain pan and lower the vehicle. PAGE 169
Transmission Replacement - General Overview Removal Procedure Warning: Refer to Battery Disconnect Warning. Caution: The drive plate (flywheel) will not support a load. None of the weight of the transmission must be allowed to rest on the drive plate during removal or installation. Caution: The transmission and torque converter must be removed and installed as an assembly to prevent damage to the front bushing or front oil seal. 1. Disconnect the battery negative cable assembly from the battery negative terminal. 2. Raise the vehicle following the manufacturer s recommendations. 3. Support the vehicle with safety stands. 4. Disconnect the range selector cable from the transmission bracket and from the range selector lever 5 Remove the transmission oil cooler pipes. Refer to Transmission Fluid Cooler Hose/Pipe Replacement. 6. Remove the rear propeller shaft. 7. Support the transmission with a transmission jack. 8. Remove the transmission rear support and insulator assembly attaching bolts at the bottom rear of the transmission. 9. Remove exhaust pipe, manifolds or exhaust components as necessary 10. Remove the converter splash shield 11. Mark the flywheel and the torque converter alignment. PAGE 170
the vehicle. 19 Raise the transmission with the transmission jack to take pressure off of the rear cross member. 20 Secure transmission to the jack with safety chain Note: If equipped, remove the starter opening shield in the starter motor mounting port in order to access the torque converter to engine flywheel bolts. 12. Remove the bolts that attach the torque converter to the engine flywheel. 13. Remove the transmission vent hose and the wiring harness from the transmission. 14. Remove the transmission fluid fill tube and the fill tube seal from the transmission. 15. Plug the fluid fill tube opening in the transmission. 16. Disconnect the transmission oil cooler pipes from the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Replacement. 17. Plug the transmission oil cooler pipe connectors in the transmission case. 18. Remove all vehicle harness wires, harness clips, tubes, brackets, and lines that may interfere with the removal of the transmission from 21. Remove the studs and the bolts securing the transmission to the engine. 22. Pull the transmission straight back. 23. Remove the transmission and converter assembly from under the vehicle. 24. Inspect all the components for wear and damage. 25. Inspect all the seals and the fittings for signs of wear. 26. Inspect the torque converter for stripped or broken weld nuts. 27. Inspect the transmission case for cracks. Installation Procedure Caution: The drive plate (flywheel) will not support a load. None of the weight of the transmission must be allowed to PAGE 171
rest on the drive plate during removal or installation. Caution: The transmission and torque converter must be removed and installed as an assembly to prevent damage to the front bushing or front oil seal. 1. Support the transmission with a transmission jack. 2 Secure the transmission to jack with a safety chain 3. Raise the transmission into place. 3. Slide the transmission straight into the engine adapter housing while lining up the pilot of the converter to the hole in the drive plate (flywheel) adapter. Caution: Refer to Fastener Caution. Note: The torque converter must be flush onto the flywheel and rotate freely by hand. Do not install the transmission fluid fill tube. 4. Install the bolts that secure the transmission to the engine or mounting plate. Tighten the studs and the bolts to 47 N m (34 lb ft). 5. Align the marks on the flywheel and the torque converter, and install the bolts securing the torque converter to the engine flywheel. 5.1 First tighten all the bolts finger tight in order to insure proper converter seating. 5.2 Tighten the bolts to 60 N m (44 lb ft). 6. Install the studs and the bolts securing the transmission to the engine. 7. Position and install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal. 8. Install the transmission fluid fill tube and the fill tube seal. Refer to Transmission Fluid Filler Tube and Seal Replacement. 9. Install the transmission vent hose and the wiring harness to the transmission. PAGE 172
10. Install the sight shield. 11. Install exhaust pipes, manifolds or exhaust components as necessary. 12. Lower the transmission with the transmission jack to put pressure on the rear cross member. 13 Position transmission rear support and insulator assembly above cross member and lower transmission into place. Install mounting bolts and tighten to 50 N m (37 lb ft) 13. Remove the transmission jack and the engine support stands. 14. Install the rear propeller shaft. 15. Install the transmission range select cable to the transmission range select lever and the bracket. 16. Install the transmission oil cooler pipes. Refer to Transmission Fluid Cooler Hose/Pipe Replacement. 17 Flush the transmission oil cooler and the pipes whenever you remove the transmission for overhaul, or replacement of the torque converter, the pump, or the transmission case. Refer to Transmission Fluid Cooler Flushing and Flow Test. 18. Remove the safety stands. 19. Lower the vehicle. 20. Fill the transmission to the proper level using DEXRON VI transmission fluid. 21. Connect the battery negative cable assembly to the battery negative terminal and tighten bolt to 15 N m (11 lb ft). PAGE 173
Special Tools Illustration Tool Number/Descripti on J 43909 J 29714 -A Servo Cover Depressor J 35944-22 Transmission Oil Cooler Flushing Fluid J 35944-200 Cooler Flushing Adapters J 36850 Transjel Lubricant Selector Shaft Seal Installer J 43911 Selector Shaft Seal Remover PAGE 174
Case Extension Assembly Seal Replacement Removal Procedure 1. Raise and suitably support the vehicle as required. Refer to manufacturer s instructions regarding Lifting and Jacking the Vehicle. 2. Support the transmission with a transmission jack. 3. Remove transmission mount. Refer to Transmission Mount Replacement. 4. Place a drain pan under the vehicle. 5. Remove the propeller shaft. 6. Remove the 2brake caliper pin bolts (1). Warning: Avoid taking the following actions when you service wheel brake parts: PAGE 175
Do not grind brake linings. Do not sand brake linings. Do not clean wheel brake parts with a dry brush or with compressed air. Some models or aftermarket brake parts may contain asbestos fibers which can become airborne in dust. Breathing dust with asbestos fibers may cause serious bodily harm. Use a water-dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to perform this washing function. These wet methods prevent fibers from becoming airborne. 7. Remove caliper assembly Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount. 8. Remove the flange yoke bolts (6), flange yoke (7), rotor (5), flange cap (4). 9. Remove the case extension bolts (2). 10. Remove the case extension (3). 11. Remove and discard the case extension O-ring seal(1). Installation Procedure 1. Install a new case extension O-ring seal (3). Caution: Refer to Fastener Caution. 2. Install the case extension (3). Rotate flange as required to align flange and output shaft splines. 3. Install the case extension bolts (2) and tighten to 45N m (33lbft). 4. Install the flange cap (4), rotor (5), flange yoke (7). PAGE 176
5. Install flange yoke bolts (6) and tighten to XX N m (XX lb ft). 6. Install transmission mount. Refer to Transmission Mount Replacement. 7. Install caliper onto rotor 8. Install the brake caliper guide pin bolts (1) and tighten to 35Nm (26lbft). 9. Remove the drain pan and the transmission jack. 10. Install the propeller shaft 11. Lower the vehicle. 12. Fill the transmission to the proper level with DEXRON VI transmission fluid. Refer to Transmission Fluid Level and Condition Check. PAGE 177
Manual No. 310547 Pr op er ty of Am er ic an Ai rli ne s TML-704H Maintenance Lift PAGE 178
Manual No. 310547 Pr op er ty of Am er ic an Ai rli ne s TML-704H Maintenance Lift PAGE 179
Manual No. 310547 Pr op er ty of Am er ic an Ai rli ne s TML-704H Maintenance Lift PAGE 180