Workshop Repair and Service Manuals GMC SIERRA
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Transmission Transaxle

03-07-29-004H Manual Transmission Operating Characteristics - (May 30 2012) Manual - part 3      The clutch brake is intendedto only be used while at a stop. Care must be taken to not activate the clutch brakewhile shifting between gears. This could lead to excessive grinding or a blocked ormissed shift. Skip Shift...
03-07-29-004H Manual Transmission Operating Characteristics - (May 30 2012) Manual - part 2      This isa light rattle, and once again, vehicles with dual mass flywheels will have reducednoise. If the engine is shut off while idling in neutral with the clutch engaged,the sudden stop of the engine will create a rapid change...
03-07-29-004H Manual Transmission Operating Characteristics - (May 30 2012) Manual      Subject: Manual Transmission Operating Characteristics Models:  2013 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior Chevrolet and GMC Medium Duty Trucks Equipped with Manual Transmission...
08-06-04-006L Information for Identifying Non-GM ECM Calibration Use and Power-up Hardware Detection in Duramax Diesel Engines - Photograph Tech 2 Calibration IDs Calibration Verification Numbers (CVNs) and Transmission Data Screen - (Jan 25 2013) Automatic Transmission Unit - part 6      Transmission Calc. Engine Torque Parameter) Take a clear digital picture in the .jpg file format of the Tech 2® screen showingthe Transmission Data and the Max. Transmission Calc. Engine Torque parameter.Retain the Tech 2®...
08-06-04-006L Information for Identifying Non-GM ECM Calibration Use and Power-up Hardware Detection in Duramax Diesel Engines - Photograph Tech 2 Calibration IDs Calibration Verification Numbers (CVNs) and Transmission Data Screen - (Jan 25 2013) Automatic Transmission Unit - part 5      1cchk23a1ar 12628694 5f763e5 12628694 12521434 12615744 12617097 673b472e Take a clear digital picture of the Tech 2® Programming History screen showing thecomplete VIN, Calibration IDs and the CVNs. Retain the printout...
08-06-04-006L Information for Identifying Non-GM ECM Calibration Use and Power-up Hardware Detection in Duramax Diesel Engines - Photograph Tech 2 Calibration IDs Calibration Verification Numbers (CVNs) and Transmission Data Screen - (Jan 25 2013) Automatic Transmission Unit - part 4      Be prepared to provide all of the usual documentationthat is normally required when requesting an assembly authorization from the PQC.2007-2013 RPO LGH, LML or LMM Instructions for Confirming Calibration VerificationNumbers...
08-06-04-006L Information for Identifying Non-GM ECM Calibration Use and Power-up Hardware Detection in Duramax Diesel Engines - Photograph Tech 2 Calibration IDs Calibration Verification Numbers (CVNs) and Transmission Data Screen - (Jan 25 2013) Automatic Transmission Unit - part 3      Go to TIS2WEB.Select: Calibration Information (SPS Info).Enter the VIN.Select: Get Cal ID.Select: ECM Engine Control Module.Select: Next.Select: Complete History.Print.Take the printout to the vehicle along with the Tech...
08-06-04-006L Information for Identifying Non-GM ECM Calibration Use and Power-up Hardware Detection in Duramax Diesel Engines - Photograph Tech 2 Calibration IDs Calibration Verification Numbers (CVNs) and Transmission Data Screen - (Jan 25 2013) Automatic Transmission Unit - part 2      GM recommends performing this check whenever a hard part failure isseen on internal engine, transmission, transfer case or rear axle components, andbefore disassembly, repair or replacement of an engine, transmission, transfer...
08-06-04-006L Information for Identifying Non-GM ECM Calibration Use and Power-up Hardware Detection in Duramax Diesel Engines - Photograph Tech 2 Calibration IDs Calibration Verification Numbers (CVNs) and Transmission Data Screen - (Jan 25 2013) Automatic Transmission Unit      Subject: Information for Identifying Non-GM ECM Calibration Use and Power-Up Hardware Detectionin Duramax™ Diesel Engines — Photograph Tech 2® Calibration IDs, Calibration VerificationNumbers (CVNs) and Transmission Data...
09-07-30-018D Warranty Administration - Change in Automatic Transmission Add Condition Documentation and Claim Submission - (May 10 2013) Automatic - part 2      Note:For reconditioning work beyond base repair, OLH must be documented by clock time whenreconditioning begins and is completed. OLH should not be used for work included inthe base repair time. Note:For steering wheel angle...
09-07-30-018D Warranty Administration - Change in Automatic Transmission Add Condition Documentation and Claim Submission - (May 10 2013) Automatic      Subject: Warranty Administration – Change in Automatic Transmission Add Condition Documentationand Claim Submission Models:  2014 and Prior GM Passenger Cars and Trucks Attention:  This bulletin applies to all...
10-07-30-001D Fluid Oil Leak During Cold Weather from Transmission Vent - (Feb 22 2013) Automatic Transmission Unit      Subject: Fluid/Oil Leak During Cold Weather from Transmission Vent Models:  2001-2013 Chevrolet Silverado 2500HD-3500HD Series 2001-2013 GMC Sierra 2500HD-3500HD Series Equipped with Allison® LCT 1000...
1-2-3-4-5-6 Clutch Piston Housing Assemble Automatic - part 3      corresponding to the highestnumber recorded in the previous step.Remove J 44525 selector from the turbine shaft. Align the selected 1–2–3–4 clutch backing plate-(3) so that the beveled edge of thebacking plate is facing...
1-2-3-4-5-6 Clutch Piston Housing Assemble Automatic - part 2      Position the 1–2–3–4, 4–5–6 clutch housing-(6) on the base of J 24204-2 assembly-(7) so that the rear of the housing is facing up.Install J 47339-1 compressor-(4) onto the shaft of J 24204-2 assembly-(7).Center J 47339-1...
1-2-3-4-5-6 Clutch Piston Housing Assemble Automatic      Special ToolsJ 24204-2 Bar and Stud AssemblyJ 36850 Transjel® LubricantJ 44525 Clutch Backing Plate SelectorJ 47339-1 Piston Return Spring CompressorJ 47339-2 Seal Area Protector For equivalent regional tools, refer toSpecial...
1-2-3-4-5-6 Clutch Piston Housing Assembly Installation Automatic      Special ToolsJ-36850 Transjel® LubricantJ-44587 Main Shaft Holder For equivalent regional tools, refer toSpecial Tools. Position the transmission case so that the front of the case is facing up.Remove 2 bolts-(2) from...
1-2-3-4-5-6 Clutch Piston Housing Assembly Removal Automatic      Lift and remove the 1–2–3–4,4–5–6 clutch pistonassembly-(1). Important:The thrust bearing assembly may stick to the1–2–3–4, 4–5–6clutch piston assembly or the input carrier assembly. Remove thrust bearing assembly-(1)...
1-2-3-4-5-6 Clutch Piston Housing Disassemble Automatic - part 2      Remove the seal rings-(1 and 2) from the1–2–3–4 clutchpiston-(3). Position the 1–2–3–4,4–5–6 clutch housing-(8) on the baseofJ 24204-2assembly-(10) so that the rear of the housing is facingup.AlignJ 47339-2protectorJ...
1-2-3-4-5-6 Clutch Piston Housing Disassemble Automatic      Special ToolsJ 24204-2Bar and Stud AssemblyJ 43772Torque Converter Seal InstallerJ 47339-1Piston Return Spring CompressorJ 47339-2Seal Area Protector For equivalent regional tools, refer toSpecial Tools. Position the...
1-2-3-4-5-6 Clutch Piston Housing Inspection Automatic      Important:The power take-off (PTO) gears are permanently staked to the1–2–3–4, 4–5–6clutch housing and are not serviceable. Turbine tone wheels areserviceable. Inspect the turbine tone wheel or PTO gear-(3) fordamage. Make...
1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly Installation (6L80 6L90) Manual Clutch      1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly Installation Callout Component Name 1 2–6 and 3–5 Reverse Clutch Hub Thrust Bearing Assembly 2 2–6 and 3–5 Reverse Clutch (with Output...
1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly Removal (6L50 80 90) Manual Clutch      1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly Removal Callout Component Name 1 1–2–3–4 and 3–5Reverse Clutch Assembly and4–5–6-(With Turbine Shaft) ClutchAssembly 2 Turbine Shaft Thrust...
1-2-3-4 and 4-5-6 Clutch Housing Reluctor Wheel Replacement Automatic      Special ToolsJ 43767Tone Wheel StakerJ 43768Tone Wheel Driver For equivalent regional tools, refer toSpecial Tools. Removal Procedure Grind the stakes from the1–2–3–4, 4–5–6clutch housing-(1). Position the 1–2–3–4,4–5–6...
1-2 Accumulator Cover Fluid Passages Automatic      1-2 Accumulator Cover Fluid Passages (20) Accumulator (21) Orificed Accumulator (25) 2nd Clutch (25) 2nd Clutch
1-3 Clutch Housing Overhaul Automatic      Table 1: 1-3 Clutch Housing Overhaul Table 2: 1–3 Piston Removal Table 3: 1–3 Piston Installation Table 4: 1–3 Clutch Plate Installation 1-3 Clutch Housing Overhaul Callout Component Name 1...
1-3 Clutch Housing Sun Gear Carrier and Sun Gear Installation Automatic      1-3 Clutch Housing, Sun Gear Carrier, and Sun Gear Installation Callout Component Name 1 Hybrid Direct, 2–3–4 Clutch HousingThrust Bearing Assembly 2 1-3 Clutch Housing Assembly ProcedureAlign the internal...
2-4 Band 3-4 Clutch Housing and Reverse Input Clutch Housing Assembly Removal Automatic Transmission Unit Trans Bands Brakes      Remove the band anchor pin-(41). Remove the input housing and shaft assembly-(621),along with the reverse input clutch housing and drumassembly-(605). Remove the 2-4 band assembly (602).
2-4 Band Installation Automatic Transmission Unit Trans Bands Brakes      Inspect the 2-4 band assembly (602) for damage orwear.Install the 2-4 band (602) into the case. Install the band anchor pin-(41) into thecase.Index the band to fit the band anchor pin into theband.
2-4 Band Servo 2nd Apply Piston Assembly Disassemble Automatic Transmission Unit Trans Band Servos      Special Tools J-22269-01Accumulator and Servo Piston Remover Use aJ-22269-01piston removerto compress the second apply piston assembly (17).Remove the second apply piston retaining ring (14).Remove the servo cushion...
2-4 Band Servo 2nd Apply Piston Assembly Installation Automatic Transmission Unit Trans Band Servos      Special ToolsJ-22269-01Accumulator and Servo Piston RemoverJ-29714-AServo Cover Depressor Inspect the 4th apply piston-(25), the2-4-servo cover-(28), the 2nd applypiston-(17), and the servo piston innerhousing-(20) for the...
2-4 Band Servo 2nd Apply Piston Assembly Removal Automatic Transmission Unit Trans Band Servos      Special Tools J-29714-AServo Cover Depressor For equivalent regional tools, refer toSpecial Tools. Install theJ-29714-Adepressor. Note:If cover does not move inwards with tool, use a block of woodor suitable material...
2-4 Band Servo Piston Pin Length Check Automatic Transmission Unit Trans Band Servos      Special Tools J-330372-4 Intermediate Band Apply Pin Gauge Disassemble the 2–4 servo assembly. Remove theapply pin retaining ring-(24), the servo apply pinwasher-(23), the servo apply pin spring-(22)and the 2nd apply...
2-4 Band Servo Piston Pin Length Check Automatic Transmission Unit Trans Band Servos      Special Tools J-330372-4 Intermediate Band Apply Pin Gauge Install the band apply pin-(13) and theJ-33037pin gauge.Install the servo cover retaining ring-(29) tosecure the tool. Apply 11-Y(98-lb-in) torque. If the...
2-4 Band Servo Piston Pin Selection Automatic Transmission Unit Trans Band Servos      2-4 Servo Pin Selection Pin Length Pin Identification mm inch 65.82–66.12 2.59–2.60 1 Groove 67.23–67.53 2.65–2.66 2 Grooves 68.64–68.94 2.70–2.71 No Groove
2-4 Servo Automatic Transmission Unit Trans Band Servos      Special Tools J 29714-A Servo Cover Depressor Removal Procedure Remove the catalytic converter pipe. Refer toCatalytic Converter Replacement.Remove the heat shield bolts.Remove the heat shield.Support the...
2-4 Servo Passages Automatic      2-4 Servo Fluid Passages (#7) 3rd Accumulator Retainer and BallAssembly (40) (#7) 3rd Accumulator Retainer and BallAssembly (40) (11) Case Servo Orificed Plug (11) Case Servo Orificed Plug (25) 2nd Clutch...
2-6 Clutch Backing Plate Inspection Automatic      Note:Perform the following measurements at 3 or morelocations. Measure the thickness of the 2–6 clutch backingplate at dimension A. Specification The 2–6 clutch backing plate minimum thickness is11.10-mm (0.4370-in).Measure...
2-6 Clutch Overhaul Automatic      Table 1: 2–6 Clutch Plates Removal Table 2: 2–6 Clutch Piston Replacement Table 3: 2–6 Clutch Plates Installation 2–6 Clutch Plates Removal 2–6 Clutch Plates Removal Callout Component Name 1 2–6...
2-6 Clutch Piston Removal Automatic      Important:The preferred method of dislodging the 2–6 clutchpiston is with compressed air. If compressed air is not available,remove the 2–6 clutch piston assembly using pliers. Ifcompressed air is used, note the following....
2-6 Clutch Plate Inspection Automatic      Note: Perform the following measurements at 3 or morelocations.Check the plates for coning on a level surface.Replace any parts not meeting specifications.Measure the thickness of each 2–6 clutch fiberplate-(1) at...
2WD Output Housing Extension Assembly - Rear Case Assembly Side Automatic      2WD Output Housing ExtensionAssembly-–-Rear Case AssemblySide (39) Seal Drainback
3-4 Accumulator Installation Automatic      Inspect the 3-4 accumulator piston (44) for the followingconditions:PorosityCracksScoringNicks and scratchesInstall the 3-4 accumulator piston oil seal ring (45) on the3-4 accumulator piston (44). Install the 3-4...
3-4 Clutch Housing with Input Shaft Inspection Automatic Transmission Unit Automatic Clutches      Inspect the input housing and shaft assembly for thefollowing conditions:PorositySpline wear-–-internal andexternalInput speed sensor models, rotor teeth for cracks ordamageThree turbine shaft ball check valves are present...
3-4 Clutch Plate Assemble Automatic Transmission Unit Automatic Clutches      Note:The part 654A may have 5, 6 or 7 plates. Inspect the 3rd and 4th clutch apply plate (653), the fiberplate assemblies (654A), the steel plates (654B) and the selectivebacking plate (655) for the following...
3-4 Clutch Plate Travel Check Automatic Transmission Unit Automatic Clutches      Use feeler gauges to check the 3rd and 4th clutch platetravel.Check the travel between the selective backing plate (655)and the first fiber plate assembly (654A). The 3rd and 4th clutch plate travel should be: Five...
3-5 Reverse Clutch Backing Plate Retaining Ring Measurement (6L80 6L90) Automatic Transmission Unit Automatic Clutches      3-5 Reverse Clutch Backing Plate Retaining Ring Measurement Callout Component Name Preliminary ProceduresInstall the 1–2–3–4 and 3–5 reverse clutch housing with the 1–2–3–4 and 3–5 reverseclutch plates installed, onto...
3-5-Reverse Clutch Piston Removal Automatic Transmission Unit Automatic Clutches      Important:The preferred method of dislodging the 3rd, 5th, and reverseclutch piston is with compressed air. Use a 9.5-mm(3/8-in) rubber hose on the air connection to reach intothe 3rd, 5th, and reverse clutch annulus port....
3rd 5th and Reverse Clutch Plate Inspection Automatic Transmission Unit Automatic Clutches      Note:Make the following measurements at 3 or more locations.Replace any parts not meeting specifications. Measure the thickness of each 3rd, 5th, and reverse clutchfiber plate-(1) at dimension A. Specification The 3rd, 5th,...
3rd 5th and Reverse Clutch Removal Automatic Transmission Unit Automatic Clutches      Special ToolsJ 24204-2Bar and Stud AssemblyJ 44530Clutch Piston Spring Compressor For equivalent regional tools, refer toSpecial Tools. Position the transmission case so that the front of thetransmission case is facing up....
3rd Accumulator Retainer with Ball Assembly Leak Check Automatic      Special Tools J-29714-A Servo Cover Depressor Install the 2-4 servo into the case. Install oil pan with only four bolts to align pan to case.Use the J-29714-A depressor in order to compress the servo cover.Install the...
3rd Accumulator Retainer with Ball Replacement Automatic      Remove the third accumulator retainer and ball assembly,using a 44.8-mm (1.763-in) #4 screwextractor. Scribe a mark at 44.8-mm(1.763-in)-(a) on a 9.5-mm(0.375-in)-(b) diameter metal rod. The scribemark is used to gauge...
4-5-6 Clutch Backing Plate Retaining Ring Measurement Automatic      4-5-6 Clutch Backing Plate Retaining Ring Measurement Callout Component Name Preliminary ProceduresInstall the clutch assembly into a hole in the workbenchZero out the dial indicator on the DT-47868-1 pack travel...
4-5-6 Clutch Dampener Overhaul (6L50 80 90) Automatic      4-5-6 Clutch Dampener Overhaul Callout Component Name 1 4–5–6 Clutch Dampener Retaining Ring Caution:Ensure the retaining ring is fully seated when installed.Using a screwdriver, fully seat the retaining ring...
4-5-6 Clutch Overhaul Automatic      Table 1: 4–5–6 Clutch Plates Removal Table 2: 4–5–6 Clutch Piston Removal Table 3: Turbine Shaft Fluid Seal Ring Replacement Table 4: 4–5–6 Clutch Piston Installation Table 5: 4–5–6 Clutch Plates...
4th Clutch Piston Installation Automatic      4th Clutch Piston Installation Callout Component Name 1 4th Clutch Piston Note:Use a 2-inch spacer between DT-48056 spring compressor bridge and DT-47694 piston spring compressor. Special ToolsDT-47694 Piston...
4th Clutch Piston Removal Automatic      4th Clutch Piston Removal Callout Component Name 1 4th Clutch Piston Retaining Ring Warning:Use care when removing or installing the retaining ring, orbodily injury may occur. 2 4th Clutch Backing Plate...
Accumulator Assembly Spacer Plate and Gaskets Automatic      Special ToolsJ 25025-BPump and Valve Body Alignment Pin SetJ 36850Transjel LubricantRemoval Procedure Raise and support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the transmission oil pan and filter. Refer...
Automatic Transmission Fluid and Filter Replacement Automatic      Removal ProcedureRaise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Place a drain pan under the transmission oil pan.Remove the oil pan drain plug, if equipped.If necessary, remove the bolts and...
Automatic Transmission Fluid and Filter Replacement (External Filter) Automatic      Removal Procedure Remove the drain plug-(6) and drain plug seal-(5). Drain the transmission fluid intoa suitable container.Inspect the drained fluid. Refer toTransmission Fluid Level and Condition Check. Note:Use a standard...
Automatic Transmission Fluid Filter and Auxiliary Fluid Pump Filter Replacement Automatic Transmission Unit Transmission Oil Pump      Automatic Transmission Fluid Filter and Auxiliary Fluid Pump Filter Replacement Callout Component Name Preliminary Procedure Remove the transmission fluid pan. Refer toTransmission Fluid Pan Replacement. 1...
Automatic Transmission Fluid Fluid Pan and or Filter Replacement Automatic      Automatic Transmission Fluid, Fluid Pan and/or Filter Replacement Callout Component Name Caution:Use Dexron-VI transmission fluid only. Failure touse the proper fluid may result in transmission internaldamage....
Automatic Transmission Fluid Pressure Test Hole Plug Replacement Automatic      Automatic Transmission Fluid Pressure Test Hole Plug Replacement Callout Component Name Preliminary Procedure Raise the vehicle. Refer toLifting and Jacking the Vehicle. 1 Transmission Fluid Pressure Test...
Automatic Transmission Fluid Pressure Test Hole Plug Replacement Automatic      Removal Procedure Remove the pressure tap plug-(2) andO-ring-(1) on the bottom of the converter housing nearthe transmission external oil filter.Remove the O-ring from the plug and discard it.Installation Procedure...
Automatic Transmission Fluid Pressure Test Hole Plug Replacement Automatic      Removal ProcedureRaise and support the vehicle. Refer toLifting and Jacking the Vehicle. Clean the surrounding area of the oil pressure testplug.Remove the oil pressure test plug.Installation Procedure Caution:Refer...
Auxiliary Fluid Pump and Gasket Replacement Automatic Transmission Unit Transmission Oil Pump      Removal Procedure Disconnect the auxiliary fluid pump wireharness-(1) from the auxiliary fluid pump control moduleconnector-(2).Remove the auxiliary fluid pump wire harness-(6)from the harness retainers-(7).Raise and...
Auxiliary Fluid Pump Control Module Replacement Automatic Transmission Unit Transmission Oil Pump      Removal Procedure Disconnect the auxiliary fluid pump electrical wire harnessconnector-(1) from the auxiliary fluid pump controlmodule connector-(2). Disconnect the auxiliary fluid pump control module...
Auxiliary Fluid Pump Installation Automatic Transmission Unit Transmission Oil Pump      Auxiliary Fluid Pump Installation Callout Component Name 1 A/Trans Auxiliary Fluid Pump Gasket Caution:The auxiliary fluid pump gasket is not re-usable.Use a NEW gasket when replacing or damage may occur. 2...
Auxiliary Fluid Pump Removal Automatic Transmission Unit Transmission Oil Pump      Auxiliary Fluid Pump Removal Callout Component Name 1 A/Trans Auxiliary Fluid PumpBolt-M6-x-1.0-x-65(Qty:-4) 2 A/Trans Auxiliary Fluid Pump Assembly Caution:Do not damage the case sealing surface when...
Backup Lamp Switch Replacement Manual      Removal Procedure Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Disconnect the backup lamp switch electricalconnector-(3). Remove the backup lamp switch.Installation Procedure...
Bar Code Label Contents Automatic      Bar Code Label Contents kc 8032a 61 okc d426403052 (1) 9 = 2009 (2) Model (3) Hydra-Matic4L60-E (4) Transmission Asm. as ShippedNumber (5) 9 = Model Year (6) Julian Date or Day of theYear (7)...
Bearings and Spacers Cleaning and Inspection Manual      Caution:When you are jacking the vehicle at the front locations, becertain that the jack or the jack lift pad does not contact thefront fascia, front fascia air dam, or the front fenders. If suchcontact occurs, vehicle...
Bearings and Spacers Cleaning and Inspection Manual      Caution:Do not allow the bearings to spin. Turn them slowly by hand.Spinning the bearings may damage the race and the rollers. Clean all bearing components in a suitable solvent and airdry.Inspect the bearings and journals...
Case Assembly - Control Valve Upper Body Assembly Side Automatic      Case Assembly-–-ControlValve Upper Body Assembly Side (5) A Cooling (6) B Cooling (18) HL 12 Clutch (25) 13 Clutch (30) HD 234 Clutch (33) 4th Clutch (41) Void
Case Assembly - Fluid Pump Cover Assembly Side Automatic      Case Assembly-–-Fluid PumpCover Assembly Side (5) A Cooling (33) 4th Clutch (40) Vent
Case Assembly Inspection Automatic      Inspect the spacer plate to case gasket for witness marks.The witness marks should be complete. Incomplete witness marks maycome from an uneven case surface or from cross channelleaks. Using compressed air, blow into all...
Case Assembly - Rear Case Assembly Side Automatic      Case Assembly-–-Rear CaseAssembly Side (6) B Cooling (18) HL 12 Clutch (25) 13 Clutch (30) HD 234 Clutch (40) Vent
Case Bushing Automatic      Special ToolsJ-8092Driver HandleJ-34196-BTransmission Bushing Service SetRemoval Procedure Remove the case bushing (7) usingJ-8092driver handle-(1) and J 34196-10-(2) which ispart of kitJ-34196-Bbushing service set....
Case Extension and Gasket Replacement Automatic      Case Extension and Gasket Replacement Callout Component Name Note:The extension housing and drive shaft flange (yoke) on this vehicle are serviced asa complete assembly. The drive shaft flange seal is a dust shield...
Case Extension and Gasket Replacement Automatic      Case Extension and Gasket Replacement Callout Component Name Caution:Use Dexron-VI transmission fluid only. Failure touse the proper fluid may result in transmission internaldamage. Preliminary ProceduresRemove the...
Case Extension Assembly Installation Automatic      Case Extension Assembly Installation Callout Component Name 1 NEW Case Extension Seal 2 Case Extension 3 Bolts-M10-x-40-(Qty:-6) Caution:Refer toFastener Caution. Procedure Tighten in sequence...
Case Extension Assembly Removal Automatic      Case Extension Assembly Removal Callout Component Name 1 Bolt-M10-x-40-(Quantity:-6) 2 Case Extension 3 Case Extension Seal
Case Extension Assembly Replacement Automatic      Removal Procedure Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Support the transmission with a transmission jack.Place a drain pan under the vehicle.Remove the propeller shaft. Refer...
Case Fluid Passages (Control Valve Body Side) Automatic      Case Fluid Passages (Control Valve Body Side) (#1) Checkball (91) (#7) 3rd Accumulator Retainer and BallAssembly (40) (#10) Checkball (42) (3) Line (3) Line (3) Line (3) Line (3) Line (9)...
Case Fluid Passages (Pump Cover Side) Automatic      Case Fluid Passages (Pump Cover Side) (3) Line (3) Line (3) Line (7) To Cooler (7) To Cooler (8) Lube from Cooler (8) Lube from Cooler (10) Oil Cooler Pipe Connector (10) Oil Cooler Pipe...
Case Inspection Automatic      Case Inspection Callout Component Name Caution:After cleaning the transmission components, allow to air dry.Do not use cloth or paper towels in order to dry any transmissioncomponents. Lint from the towels can cause...
Case - Top Channel Plate Side Automatic      Case– Top Channel Plate Side (9) Center Lube (29) CBR1 (Manual 1st) (30) CBR (Reverse) (46) 26 Clutch (52) Void
Center Support Assembly - Case Assembly Side Automatic      Center SupportAssembly-–-Case AssemblySide (25) 13 Clutch
Center Support Assembly Installation Automatic      Center Support Assembly Installation Callout Component Name 1 Center Support Assembly 2 Center SupportBolt-M6-x-1.0-x-20(Qty:-4) Caution:Refer toFastener Caution. Tighten 9–13-Y(80–115-lb-in)
Center Support Assembly Removal Automatic      Center Support Assembly Removal Callout Component Name 1 Center SupportBolt-M6-x-1.0-x-20.0-(Qty:-4) 2 Center Support Assembly
Center Support Cleaning and Inspection Automatic      Center Support Cleaning and Inspection Callout Component Name 1 1-3 Clutch Housing Fluid Seal Ring Note:Install a NEW seal. Discard the old seal, it is not reusable. 2 Alignment Hole 3 Seal Ring...
Center Support Output Carrier and Output Shaft Installation (6L80 6L90) Automatic      Center Support, Output Carrier and Output Shaft Installation Callout Component Name 1 Output Shaft Thrust Bearing Assembly 2 Output Carrier Assembly and Output Shaft Assembly Caution:Apply automatic...
Center Support Output Carrier and Output Shaft Removal (6L80 6L90) Automatic      Center Support, Output Carrier and Output Shaft Removal Callout Component Name 1 Center Support Retaining Ring Warning:Use care when removing or installing the retaining ring.Ensure the J-45126 and DT-47773 are...
Clutch Air Check Automatic      Inspection Procedure Important:When the overrun clutch is checked, the air will blow by theforward clutch piston lip seals and exit out of the forward clutchfeed hole in the turbine shaft. Apply air into the feed holes in...
Clutch Assembly Replacement Manual Clutch      Special Tools J-5824-A Clutch Alignment Tool Removal ProcedureRemove the transmission. Refer toTransmission Replacement. Remove the clutch pressure plate bolts. Note:Dowel pins are used to align the flywheel and pressure...
Clutch Housing Assemble Manual      Install the 4-clutch housing screws. Install the 2-interior housing nuts.
Clutch Housing Disassemble Manual      Only some applications require the removal of the clutchhousing. Remove the 2-interior clutch housing nuts. Remove the 4-clutch housing screws. Using a screwdriver, carefully separate the housing from thecase.
Clutch Master Cylinder Replacement Manual Clutch Clutch Master Cylinder      Removal Procedure Disconnect the clutch pedal position switch electricalconnector-(1).Push the clutch pedal in and squeeze the pushrod bushing tabsin, in order to release the pushrod bushing from the clutchpedal....
Clutch Pedal Replacement Manual Clutch Clutch Pedal Assy      Removal ProcedureMove the instrument panel to the service position. Refer toInstrument Panel Service Positioning. Disconnect the clutch pedal engine start switch electricalconnector-(1).Remove the clutch master cylinder....
Clutch System Description and Operation Manual Clutch - part 3      During engagement, the disc is clamped against the flywheelby the pressure plate. The flywheel acts as a heat sink,dissipating heat and moving it away from the clutch pressure plateand disc friction material. The flywheel must...
Clutch System Description and Operation Manual Clutch - part 2      The piston is at the furthest position from thetransmission with a new clutch. Self-Adjusting Pressure Plate Assembly The self-adjusting diaphragm spring clutchconsists of a pressure plate-(1), a diaphragmspring-(5), a ramp...
Clutch System Description and Operation Manual Clutch      This vehicle uses 2-different clutch hydraulicsystems and 2-different clutch variations. The vehicleswith the 5-speed transmission RPO-TZO uses adifferent clutch hydraulic system than the vehicles with the5-speed transmission...
Control and Shift Solenoids Replacement Automatic Transmission Unit Transmission Shift Solenoids      Removal Procedure ml nu Remove the transmission oil pan and filter. Refer toAutomatic Transmission Fluid and Filter Replacement. Note:Do not remove the valve body for the following procedures.Removal of the 1-2 accumulator...
Control Solenoid (w Body and TCM) Valve Assembly - Control Valve Channel Plate Side Automatic      Control Solenoid-(w/Body and TCM) ValveAssembly-–-Control Valve ChannelPlate Side (10) Actuator Feed Limit (11) PS1 (12) PCS Line (15) PCS 3 Signal (19) PCS 4 Signal (20) Solenoid 1 Signal (21)...
Control Valve Assembly Assemble Automatic      Table 1: Valve Assembly to Channel Plate Assemble Table 2: Filter Plate Installation Table 3: Control Solenoid (w/Body and TCM) Valve Installation Table 4: Control Valve Body, Upper and Lower Assembly...
Control Valve Assembly Disassemble Automatic      Table 1: Manual Shaft Detent Assembly Removal Table 2: Control Solenoid Valve and Valve Body Assembly Disassemble Table 3: Valve Assembly and Channel Plate Disassemble Manual Shaft Detent Assembly Removal...
Control Valve Assembly Installation Automatic      .. Control Valve Assembly Installation Callout Component Name 1 Control Valve Upper Body Seal-(Qty:-6) Note:Install a NEW seal. 2 A/Trans Fluid Pump Seal Assembly Note:Install a NEW seal assembly. 3...
Control Valve Assembly Removal Automatic      Remove 2 detent spring bolts-(1).Remove the manual shift shaft detent spring-(2)from the manual shift shaft detent lever/IMSassembly-(3) and the control valve bodyassembly-(4). Remove 15 control valve body...
Control Valve Assembly Removal Automatic      Control Valve Assembly Removal Callout Component Name 1 Control Solenoid (with Body and TCM) Valve Assembly Procedure Disconnect the wiring harness. 2 Shift Shaft Position Switch Procedure Disconnect...
Control Valve Body and Wiring Harness Removal Automatic Transmission Unit Control Valve Body      ml nu Remove all electrical connectors-(1–6)from the electrical components. Remove the torque converter clutch pulse widthmodulation-(TCC/PWM) retainerclip-(395).Remove the TCC/PWM solenoid-(396). Remove the TCC...
Control Valve Body Assemble Automatic Transmission Unit Control Valve Body      Inspection Procedure Inspect the valve body to spacer plate gasket for valve bodychannel witness marks. The witness marks should be complete.Incomplete witness marks may be caused by an uneven case surface.Incomplete...
Control Valve Body Assemble Automatic Transmission Unit Control Valve Body - part 2      seat the solenoid.Install the solenoid retainer-(1). gt Note: P/N 29541898 is printed on the torque converter clutch pressure control solenoid-(TCC-PCS).The solenoid O-rings are green.O-ring-(4) is slightly larger than...
Control Valve Body Assemble Automatic Transmission Unit Control Valve Body      Special ToolsJ 33163 Valve Tray SetJ 43773 Valve Spring Compressor For equivalent regional tools, refer toSpecial Tools. Position main valve body assembly-(4) on the work table so that the worm-track sideis up.Align...
Control Valve Body Assembly Assemble Automatic Transmission Unit Control Valve Body - part 2      alve Body, Control Solenoid Torque Sequence ill Valve Body, Control Solenoid Torque Sequence Callout Component Name Caution:Bolt torque sequencing is critical to the proper function ofthe control solenoid valve...
Control Valve Body Assembly Assemble Automatic Transmission Unit Control Valve Body      Table 1: Upper to Lower Control Valve Body Assembly Assemble Table 2: Filter Plate Installation Table 3: Control Solenoid Valve Assembly Installation Table 4: Manual Shift Shaft Position Switch Installation...
Control Valve Body Assembly Disassemble Automatic Transmission Unit Control Valve Body      Table 1: Input and Output Speed Sensor Assembly Removal Table 2: Manual Shaft Detent Assembly and Manual Shift Shaft Position Switch Removal Table 3: Control Solenoid Valve Assembly Removal Table 4: Upper...
Control Valve Body Assembly Disassemble Automatic Transmission Unit Control Valve Body      Special Tools J 33163Valve Tray Set For equivalent regional tools, refer toSpecial Tools. Caution:DO NOT damage the solenoids when turning over the controlvalve assembly. Note:To help prevent confusing parts on...
Control Valve Body Assembly Installation Automatic Transmission Unit Control Valve Body      Control Valve Body Assembly Installation Callout Component Name 1 NEW Fluid Pump Seal Assembly 2 NEW Fluid Pump Seal Assembly 3 NEW Center Support Fluid Passage Seal Assembly Note:There are two...
Control Valve Body Assembly Installation Automatic Transmission Unit Control Valve Body      Note:Installing a lint-free cloth into the park pawl cam guidehole prevents the manual valve pin from falling into thetransmission. Install a lint-free cloth-(1) in the park pawl camguide hole in the transmission...
Control Valve Body Assembly Removal Automatic Transmission Unit Control Valve Body      Control Valve Body Assembly Removal Callout Component Name 1 Bolt-M5-x-73-(Qty:-6) Note:Do not remove all the bolts in the control valve body assembly. Remove only the boltsindicated. Special Tool DT-48285...
Control Valve Body Cleaning and Inspection Automatic Transmission Unit Control Valve Body      Clean and Inspect Caution:Refer toTransmission Control Valve Body Overhaul Caution. Clean all removed parts with volatile mineral spirits orother similar cleaning agent.Clean fluid passages by working a piece of soft wire...
Control Valve Body Disassemble Automatic Transmission Unit Control Valve Body      Warning:Refer toValve Springs Can Be Tightly Compressed Warning. Remove the manual valve-(340). Remove the forward accumulator cover bolts-(364)and the forward accumulator cover-(363).Remove the forward accumulator...
Control Valve Body Fluid Passages (Case Side) Automatic      Control Valve Body Fluid Passages (Case Side) (#2) Checkball (61) (#3) Checkball (61) (#4) Checkball (61) (#5) Checkball (61) (#6) Checkball (61) (#8) Checkball (61) (#12) Checkball (61) (3)...
Control Valve Body Installation Automatic Transmission Unit Control Valve Body      Special ToolsJ-25025-5Dial Indicator MountingPost–M6-x-1.00J-36850Transjel Lubricant Inspect the wiring harness and solenoid assembly for thefollowing conditions:DamageCracked connectorsExposed wiresLoose electrical...
Control Valve Body Locating Pin Replacement Automatic Transmission Unit Control Valve Body      Special Tools J 43779Locating Pin Installer For equivalent regional tools, refer toSpecial Tools. Caution:DO NOT mar the main valve body surface when installing thelocating pin(s). Tap gently on the locating pin...
Control Valve Body Replacement Automatic Transmission Unit Control Valve Body      Removal ProcedureRemove the fluid level indicator.Raise the vehicle. Refer toLifting and Jacking the Vehicle.Remove the oil pan, gasket, and filter. Refer toAutomatic Transmission Fluid and Filter Replacement. ml nu...
Control Valve Body Spacer Plate Assembly - Control Valve Upper Body Assembly Side Automatic      Control Valve Body Spacer Plate Assembly – BottomChannel Plate Side 12 34 35 29/28 15 13 34 34 3054 15 29 25 15 37/53 48 50 (2) Line (8) Cooler Feed (9) Center Lube (10) Regulator Apply (11) Compensator...
Control Valve Body Spacer (w Gasket) Plate Assembly - Control Valve Upper Body AssemblySide Automatic      Control Valve Body Spacer-(w/Gasket) PlateAssembly-–-Control Valve Upper BodyAssembly Side 25 25 11 204 (2) Line (3) Line or Auxiliary Line (5) A Cooling (6) B Cooling (10) Actuator Feed Limit (11)...
Control Valve Channel Plate - Control Solenoid Valve Assembly Side Automatic      Control Valve ChannelPlate-–-Control Solenoid ValveAssembly Side (10) Actuator Feed Limit (11) PS1 (12) PCS Line (15) PCS 3 Signal (19) PCS 4 Signal (20) Solenoid 1 Signal (21) PS3 (22) PS4...
Control Valve Channel Plate - Control Valve Upper Body Assembly Side Automatic      Control Valve ChannelPlate-–-Control Valve Upper BodyAssembly Side (2) Line (3) Line or Auxiliary Line (5) A Cooling (6) B Cooling (10) Actuator Feed Limit (11) PS1 (12) PCS Line (14)...
Control Valve Lower Body Assembly - Control Solenoid Valve Assembly Side Automatic      Control Valve Upper Body Assembly – ControlSolenoid Valve Assembly Side (12) Actuator Feed Limit (17) Solenoid 1 (18) Solenoid 2 (38) PCS TCC (39) PCS1-2-3-4 Clutch (40) PS4 (41) PS1 (42) PS3...
Control Valve Lower Body Assembly - Control Valve upper Body Assembly Side Automatic      Control Valve Lower Body Assembly – Control ValveUpper Body Assembly Side (2) Line (9) Center Lube (10) Regulator Apply (11) Compensator Feed (12) Actuator Feed Limit (13) Reverse (14) 3-5...
Control Valve Solenoid Replacement (PCS1 and PCS2) Automatic      Removal Procedure Remove the oil pan and transmission internal oil filter.Refer toOil Pan Replacement.Disconnect the internal wiring harness from the solenoidbeing changed.Remove the 2 bolts that fasten reverse...
Control Valve Upper Body Assembly - Case Assembly Side Automatic      Control Valve Upper BodyAssembly-–-Case AssemblySide __ 38 3838 (2) Line (5) A Cooling (6) B Cooling (12) PCS Line (14) Auxiliary Line (18) HL 12 Clutch (25) 13 Clutch (30) HD 234 Clutch...
Control Valve Upper Body Assembly - Case Side Automatic      Control Valve Upper Body Assembly – Case Side (2) Line (9) Center Lube (10) Regulator Apply (11) Compensator Feed (14) 3-5 Reverse Clutch (26) 1-2-3-4 Clutch (29) CBR1 (Manual 1st) (30) CBR...
Control Valve Upper Body Assembly - Control Valve Channel Plate Side Automatic      Control Valve Upper BodyAssembly-–-Control Valve ChannelPlate Side (2) Line (3) Line or Auxiliary Line (5) A Cooling (6) B Cooling (10) Actuator Feed Limit (11) PS1 (12) PCS Line (14)...
Control Valve Upper Body Assembly - Lower Control Valve Body Side Automatic      Control Valve Upper Body Assembly – Bottom ChannelPlate Side (2) Line (9) Center Lube (10) Regulator Apply (11) Compensator Feed (12) Actuator Feed Limit (13) Reverse (14) 3-5 ReverseClutch...
Converter Housing Removal Automatic      Special ToolsDT-49037MorTorq BitJ-41510T-50 Plus Bit For equivalent regional tools, refer toSpecial Tools. Remove the converter housing bolts (94). Use theJ-41510T-50 plus bitfor bolt-(1) andDT-49037mortorq bitfor...
Counter Gear Shaft and Components Manual      Counter Gear Shaft and Components (1) Front Bearing Cover (2) Front Bearing Race (3) Front Bearings and Rollers (4) Counter Shaft (5) Rear Bearing (6) Rear Bearing Race (7) Rear Bearing Adjuster...
Counter Gear Shaft Assemble Manual      Using a driving tool, install the bearing. Install the gear assembly. Install the bearing and the gear assembly bearingrace. Install the 2-caged gears, with the rollers andspacer, into the reverse gear. Install...
Counter Gear Shaft Disassemble Manual      Use an impact gun to loosen and remove the nut from the mainshaft. Remove the yoke flange from the main shaft, asnecessary. Using a 10-mm socket, remove the vehicle speedsensor-(VSS) screw. Remove the VSS....
Counter Gear Shaft Reverse Idler and Components Manual      Counter Gear Shaft, Reverse Idler, and Components (1) Center Gear Front BearingSpacer (2) Center Gear Bearing Shim (3) Center Gear Front Bearing (4) Center Gear Front BearingAssembly (5) Center Gear Front...
Default Forward - 3rd Range Limp Home Automatic      If electrical power is interrupted while the transmission isin third range, SS1 and the torque converterclutch-(TCC) solenoid (if TCC is applied) arede-energized. Shift valve-1 de-strokes, changing theexhaust path of the 4-5-6...
Default Reverse - Limp Home Automatic      If electrical power is interrupted with the transmissionoperating in reverse range, resulting in neutral operation, mainpressure is directed through shift valve-3 to shiftvalve-2. Because shift valve-2 stays strokeddue to the...
Differential Drive Pinion Gear Yoke Replacement Automatic      Removal Procedure Place the transmission in the Park-(P) selector position. Warning:Apply the parking brake and block the drive wheels beforeperforming this procedure in order to prevent bodily injury. Apply the parking...
Direct Clutch Housing Bushing Replacement Automatic Transmission Unit Automatic Clutches      Tools RequiredGE-8092 Driver HandleJ 43778 Clutch Bushing InstallerRemoval Procedure Important:DO NOT score the 1–2–3–4, 4–5–6 clutch housing bore when removing the clutch housingbushing. Gently tap the bushing through the...
Drain Oil Automatic      Rotate the transmission so that the converter housing is up.Allow the transmission fluid to drain from the caseextension.
Drive Range Fifth Gear Default Automatic      If the transmission is in 4th, 5th or 6th gear during atransmission electrical component failure, the transmission willdefault to 5th gear. All solenoids will default to their normalstate. If the torque converter clutch was...
Drive Range First Gear Automatic      As the vehicle speed increases, the transmission controlmodule-(TCM) receives input signals from the automatictransmission input and output speed sensors, throttle positionsensor and other vehicle sensors to determine the...
Drive Range First Gear Automatic      When the gear selector lever is moved to the OverdriveRange-(D) position from the Neutral-(N)position, after the first 1–2 shift has occurred, thefollowing changes occure to shift the transmission into OverdriveRange – First...
Drive Range - Fourth Gear Automatic      As vehicle speed increases, the TCM processes input signalsfrom the input and output speed sensors, the TP sensor and othervehicle sensors to determine the precise moment to command ON thenormally high pressure control...
Drive Range Second Gear Automatic      As vehicle speed increases and operating conditions becomeappropriate, the transmission control module-(TCM)processes input signals from the input and output speed sensors,the throttle position-(TP) sensor and other...
Drive Range Third Gear Default Automatic      If the transmission is in 1st, 2nd or 3rd gear during atransmission electrical component failure, the transmission willdefault to 3rd-gear. All solenoids will default to theirnormal state. If the torque converter clutch was...
Electronic Component Description Automatic      Control Solenoid (W/Body and TCM) Valve Assembly (1) Line Pressure Control (PC)Solenoid (2) Torque Converter Clutch (TCC)Pressure Control (PC) Solenoid (3) Shift Solenoid (SS) 2 (4) 16 Pin Connector (5)...
Electronic Component Description Automatic - part 3      Bothsolenoid types have an orifice, electrical windings, an iron core,and a steel check ball. Shift solenoids provide the necessary logic to distributefluid to the correct clutches. The shift solenoids provide eitherfull...
Electronic Component Description Automatic - part 2      This position iscommunicated to the TCM so that certain vehicle control functionscan be coordinated with the position of the shift controls. The IMShas redundant circuitry to alert the TCM in the event of a singlewire or switch...
Electronic Component Description Automatic      Transmission Control Module A microcomputer controls the transmission by receiving andprocessing signals from various switches and sensors. Themicrocomputer determines shift sequences, shift timing, and clutchapply and...
Electronic Component Description Automatic - part 4      EV Mode 2 As vehicle speed increases, the system shifts to EV Mode-2. EV Mode 2 uses a compoundsplit configuration to transfer power through the transmission during higher speedoperating conditions such as highway cruising....
Electronic Component Description Automatic - part 3      The sensor faces the hybrid direct, 2-3-4 clutch housing assemblymachined teeth surface. The sensor receives 8.3–9.3-volts on the OSS supply voltagecircuit from the transmission control module-(TCM). As the output shaft...
Electronic Component Description Automatic - part 2      Control Solenoid Valve Assembly (1) Pressure ControlSolenoid-2 (2) Pressure ControlSolenoid-4 (3) ShiftSolenoid-2 (4) 16 Pin Connector (5) Line Pressure ControlSolenoid (6) Transmission Fluid...
Electronic Component Description Automatic      Electronic Components (6) A/Trans Auxiliary Fluid PumpAssembly (31) A/Trans Manual Shift Shaft PositionSwitch Assembly (71) Drive Motor (w/Generator)Assembly-–-1st Position (88) Drive Motor...
Engine Flywheel Cleaning and Inspection Flywheel Flexplate      Important:In order to maintain the proper component balance, contactsurface taper, and heat transfer, manual transmission flywheels areNOT to be machined. Clean the flywheel assembly.Inspect the flywheel assembly for cracks...
Engine Flywheel Cleaning and Inspection Flywheel Flexplate      Note:In order to maintain the proper component balance, contactsurface taper and heat transfer, manual transmission flywheels areNOT to be machined. Warning:Refer toSafety Glasses Warning. Clean the engineflywheel-(1-or-2)...
Engine Flywheel Installation (Automatic Transmission) Flywheel Flexplate      Special ToolsJ 44643 Flywheel Hold ToolJ 45059 Angle Meter For equivalent regional tools, refer toSpecial Tools. Install the flywheel to the crankshaft.Install the flywheel washer to the flywheel with the beveled side...
Engine Flywheel Installation Flywheel Flexplate      Note:If replacing the engine flywheel, manual transmission, notethe position and length of the original flywheel weights, ifapplicable. Flywheel weights of the same length must be installedinto the new engine flywheel in...
Engine Flywheel Installation Flywheel Flexplate      Note: For manual transmission applications, note the position and direction of the engineflywheel before removal. Mark or scribe the end of the crankshaft and flywheel beforecomponent removal. The existing manual...
Engine Flywheel Removal (Automatic Transmission) Flywheel Flexplate      Special Tools J 44643Flywheel Hold Tool For equivalent regional tools, refer toSpecial Tools. Remove the flywheel mounting bolts and discard.Remove the flywheel washer.Remove theJ 44643tool.Remove the flywheel assembly.
Engine Flywheel Removal Flywheel Flexplate      Important:For manual transmission applications, note the position anddirection of the engine flywheel before removal. The flywheel doesnot use a locating pin for alignment. Mark or scribe the end of thecrankshaft and the...
Engine Flywheel Removal Flywheel Flexplate      Remove the engine flywheel bolts.Remove the engine flywheel-(1), automatictransmission, if applicable.Remove the engine flywheel-(2), manualtransmission, if applicable. Important:If replacing the engine flywheel, manual...
Engine Flywheel Replacement Flywheel Flexplate      Special ToolsJ 44643 Flywheel Holding Tool.J 45059 Angle Meter. For equivalent regional tools, refer to Special ToolsSpecial Tools. Removal Procedure Remove the transmission. Refer toTransmission Replacement.Install the J...
Engine Flywheel Replacement Flywheel Flexplate      Removal Procedure If equipped with an automatic transmission, remove the automatic transmission . RefertoTransmission Replacement.If equipped with a manual transmission, remove the clutch assembly. Refer toClutch Assembly...
Engine Flywheel Replacement Flywheel Flexplate      Removal ProcedureRemove the clutch assembly. Refer toClutch Assembly Replacement. Important:Note the position and direction of the engine flywheel before removal. The flywheeldoes not use a locating pin for alignment. Mark...
EVT Mode High - From Drive Range 4th Gear Automatic      EVT Mode High is used to maximize engine efficiency and fueleconomy under most normal driving conditions. The TCM processesinput signals from the input and output speed sensors, the TPsensor and other vehicle sensors to...
Exhaust Gas Recirculation Cooler Bypass Valve Replacement Automatic Transmission Oil Cooler      Exhaust Gas Recirculation Cooler Bypass Valve Replacement Callout Component Name Preliminary ProcedureRemove the turbocharger exhaust pipe. Refer toTurbocharger Exhaust Pipe Replacement.Remove the exhaust gas...
Fiber 4-5-6 Clutch Plate Inspection Automatic      Important: Measure as described below at a minimum of 3locations.Replace any 4–5–6 clutch fiber plate thatdoes not meet specifications.Measure the thickness of each 4–5–6clutch fiber plate-(1) at dimension A. Specification...
Fifth Range Automatic - part 2      The 3rd, 5th, and reverseclutch remains applied. With only one clutch applied, thetransmission goes to neutral. If electrical power is interrupted while the transmission isin fifth range, (fifth range converter operation) and...
Fifth Range Automatic      Before making a shift from fourth to fifth range, thetransmission control module-(TCM) makes certain all ofthe shift valves are in the correct position with shiftvalve-1 and shift valve-3 stroked and shiftvalve-2 de-stroked....
First Range Automatic - part 2      If electrical power is interrupted while the transmission isin first range, moving the manual selector valve toNeutral-(N) will cut off main pressure to the 1-2-3-4clutch and the clutch will be exhausted. The low and reverse...
First Range Automatic      When the selector lever is moved from Neutral-(N)to Drive-(D), the transmission shifts from neutral tofirst range operation. Shiftsolenoid-1-(SS1), SS2, and SS3 remainenergized. Pressure control solenoid-1-(PCS1)and the torque...
Fluid Filter and Manual Shift Detent Assembly Installation Automatic      Fluid Filter and Manual Shift Detent Assembly Installation Callout Component Name 1 Manual Shaft Detent Assembly Caution:Ensure the manual shaft detent assembly roller is centeredover the manual shaft detent...
Fluid Pump Cover Assembly - Case Assembly Side Automatic      Fluid Pump CoverAssembly-–-Case AssemblySide (1) Suction (2) Line (4) Decrease (9) Regulator Lube (12) PCS Line (13) Auxiliary Suction (14) Auxiliary Line (38) Exhaust (39) Seal Drainback...
Fluid Pump Cover Assembly - Torque Dampener Housing Assembly Side Automatic      Fluid Pump CoverAssembly-–-Torque Dampener HousingAssembly Side (1) Suction (2) Line (4) Decrease (7) Cooler Feed (8) Lube (9) Regulator Lube (12) PCS Line (13) Auxiliary Suction (14)...
Fluid Pump Cover - Case Side Automatic      Fluid Pump Cover – Case Side (1) Suction (2) Line (9) Center Lube (10) Regulator Apply (11) Compensator Feed (14) 3-5 ReverseClutch (26) 1-2-3-4 Clutch (34) 4-5-6Clutch (38) PCS TCC...
Fluid Pump Cover Cleaning and Inspection Automatic Transmission Unit Transmission Oil Pump      Fluid Pump Cover Cleaning and Inspection Callout Component Name Warning:Valve springs can be tightly compressed. Use care whenremoving retainers and plugs. Personal injury could result. Preliminary Procedure Clean...
Fluid Pump Cover Installation Automatic Transmission Unit Transmission Oil Pump      Fluid Pump Cover Installation Callout Component Name 1 Fluid Pump Cover Assembly 2 Fluid Pump Cover Bolts-M6-x-40-(Qty:-13) Note:Hand tighten only. 3 Alignment Tool and Bolt Caution:Refer...
Fluid Pump Cover Installation Automatic Transmission Unit Transmission Oil Pump      Fluid Pump Cover Installation Callout Component Name 1 A/Trans Fluid Pump Cover Assembly Note:Align pump with guide pins on the torque dampener housing. 2 A/Trans Fluid Pump Cover Bolts-M6-x1.0-x-45...
Fluid Pump Cover - Torque Converter Housing Side Automatic      Fluid Pump Cover– Torque Converter HousingSide (1) Suction (2) Line (4) Converter Feed (5) Converter Feed Limit (6) TCC Release (7) TCC Apply (8) Cooler Feed (9) Center Lube (10) Regulator...
Fluid Pump Rotor and Slide Measurement Automatic Transmission Unit Transmission Oil Pump      203 Important:Measure the rotor and slide thickness for surface wear. Therotor and slide measurements must both fall into the same thicknessrange. If the rotor and slide measurements do not fall into thesame thickness...
Fluid Pump Selective Measurement Automatic Transmission Unit Transmission Oil Pump      03 inch leara use spr1 (red) for .002 to .006 inch Fluid Pump Selective Measurement Callout Component Name Preliminary ProceduresClean and inspect all components and machined surfaces.After cleaning the transmission...
Fluid Pump Selective Measurement Automatic Transmission Unit Transmission Oil Pump      Fluid Pump Selective Measurement Callout Component Name 1 Pump Rotor Cavity Note:Measure the distance from the bottom of the gauge bar to the bottom of the pump rotorcavity. Refer toFluid Pump Selective...
Flywheel Housing Cleaning and Inspection Flywheel Flexplate      Remove the O-rings from the flywheel housing anddiscard.Clean the flywheel housing.Clean the flywheel housing mating surfaces.Clean the flywheel housing O-ring sealing area.Inspect the flywheel housing for cracks.Inspect...
Flywheel Housing Installation Flywheel Flexplate      Install the oil cooler adapter-(3) withgaskets-(1) and (4) to the oil cooler. Caution:Refer toFastener Caution. Install the oil cooler adapter to oil coolerbolts-(2) and tighten to25-Y(18-lb-ft).Apply a 2–3-mm wide...
Flywheel Housing Removal Flywheel Flexplate      Special Tools J 37228Seal Cutter For equivalent regional tools, refer toSpecial Tools. Remove the turbocharger oil return pipe nuts-(1)from the top of the flywheel housing.Remove the turbocharger oil return...
Flywheel Housing Replacement Flywheel Flexplate      Special Tools J 37228 Seal Cutter Removal Procedure Drain the cooling system. Refer toCooling System Draining and Filling.Remove the crankshaft rear oil seal. Refer toCrankshaft Rear Oil Seal Removal.Remove the...
Forward Clutch Assembly Assemble Automatic Transmission Unit Automatic Clutches      Inspect the forward clutch waved plate-(648), theapply plate-(646), the fiber plateassemblies-(649B), the steel plates-(649A)and the selective backing plate-(650) for the followingconditions:Damaged...
Forward Clutch Piston Travel Check Automatic Transmission Unit Automatic Clutches      Use feeler gauges to check the forward clutch plate travel.Check travel between the forward clutch backing plate retainerring-(651) and the forward clutch selective backingplate-(650). The forward clutch plate travel should...
Forward Clutch Sprag Assemble Automatic Transmission Unit Automatic Clutches      Inspect the forward sprag assembly (642) for the followingconditions:Wear or damageWeak or broken springsInspect the forward clutch outer race (644) for the followingconditions:Race wear or damageSpline wearSurface finish...
Forward Clutch Sprag Disassemble Automatic Transmission Unit Automatic Clutches      Remove the overrun clutch hub retaining snap ring(638).Remove the overrun clutch hub (639).Remove the forward sprag clutch inner race and input sun gearassembly (640). Remove the sprag assembly retainer rings...
Fourth Range Automatic - part 2      The TCC is now released. If electrical power is interrupted while the transmission isin fourth range (causing fifth range converter operation) and themanual selector valve is moved to Neutral-(N), the 4-5-6clutch exhausts...
Fourth Range Automatic      Before making the shift from third to fourth range, thetransmission control module-(TCM) makes certain all ofthe shift valves are in the correct position, with shiftvalve-1 stroked and shift valve-2 and shiftvalve-3...
Four-Wheel-Drive Low and Reverse Clutch Housing Spacer Measurement Automatic Transmission Unit Automatic Clutches      Position the transmission case so that the rear of the caseis facing up.At dimension A, measure the distance from the rear face ofthe low and reverse clutch housing-(1) to the rear faceof the bearing spacer-(2). At...
Four-Wheel-Drive Output Shaft Bushing Inspection Automatic      Inspect the output shaft bushing-(2) for wear ordamage.Measure the inside diameter-(ID) of thebushing-(2) at dimension A.Replace the bushing If the ID of the bushing exceedsspecifications. Specification The bushing maximum...
Four-Wheel-Drive Output Shaft Retaining Nut Installation Automatic      Special Tools DT-50689Spanner Nut Wrench – 4WD For equivalent regional tools, refer toSpecial Tools. 77.8 The fullest clockwise position of the manual shift shaft isPark-(P), which engages the park pawl.Using a wrench on...
Front Output Shaft and Input Shaft Cleaning and Inspection      Front Output Shaft and Input Shaft Cleaning and Inspection Callout Component Name Preliminary ProcedureInspect all components or sub-components and perform any repair procedure necessaryto fix the damage. If the...
Front Output Shaft Drive Sprocket Bearing Replacement      Front Output Shaft Drive Sprocket Bearing Replacement Callout Component Name Preliminary ProcedureUsing the J-35512 bearing installer and an arbor press, remove the bearing assemblies from the drive sprocket.Ensure...
Front Output Shaft Drive Sprocket Bearing Replacement      Front Output Shaft Drive Sprocket Bearing Replacement Callout Component Name Preliminary ProcedureUsing the J 35512 inner pinion bearing installer and an arbor press, remove the bearing assemblies from the drive...
Front Output Shaft Front and Rear Bearing Replacement      Front Output Shaft Front and Rear Bearing Replacement Callout Component Name Preliminary ProcedureEnsure the bearings are installed squarely on the front output shaft.Using a suitable adapter and an arbor press,...
Front Output Shaft Front Bearing Replacement      Front Output Shaft Front Bearing Replacement Callout Component Name Preliminary ProcedureEnsure the bearing is installed squarely on the front output shaft.Using a suitable adapter and an arbor press, remove the...
Front Output Shaft Rear Bearing Replacement      Front Output Shaft Rear Bearing Replacement Callout Component Name Preliminary Procedure Ensure the bearing is installed squarely into the bearing bore. 1 Transfer Case Front Output Shaft Rear Bearing...
Front Output Shaft Seal Replacement      Special ToolsGE-8092 Driver HandleJ 43484 Output Shaft Seal Installer For equivalent regional tools, refer toSpecial Tools. Removal Procedure Raise and suitably support the vehicle. Refer toLifting and Jacking the...
Front Output Shaft Seal Replacement      Special ToolsJ-8092 Driver HandleDT-50649 Seal Installer For equivalent regional tools, refer toSpecial Tools. Removal ProcedureRaise and support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the transfer case...
Gears and Shafts Cleaning and Inspection Manual - part 3      Such severe deformation of the selectorteeth edges will cause hard gear shift changes. The spline flanksmay also show signs of wear resembling fretting corrosion. If gear change damage is present, replace or repair theaffected...
Gears and Shafts Cleaning and Inspection Manual - part 2      Inadequate oil viscosityUnfavorable gear geometryTemporary lack of lubricantSurface roughnessFaulty heat treatment of the gears Inspect the gears for flank fatigue causing grayspots. Gray spots are localized pittings on the...
Gears and Shafts Cleaning and Inspection Manual      Clean all the components in a suitable solvent and airdry.Inspect the gears for break-in-wear– running-in-wear. Break-in-wear is not considered to bedamage because it usually ceases after therunning-in-period has expired,...
High Low Shift Fork Replacement Manual Transmission Assembly Shift Fork      High/Low Shift Fork Replacement Callout Component Name 1 Transfer Case High/Low Shift Fork Pin Note:Drive the pin out using a drift punch and hammer. 2 Transfer Case High/Low Shift Fork Note:Inspect for...
Holding Fixture Installation and Torque Dampener Removal Automatic      Holding Fixture Installation and Torque Dampener Removal Callout Component Name 1 A/Trans Torque Dampener Assembly Special Tools J 21366 Converter Holding Strap 2 A/Trans Case Assembly ProcedureRotate...
Holding Fixture Installation Automatic      Special Tools J 44723Transmission/Stand Adapter Plate For equivalent regional tools, refer toSpecial Tools. Warning:The torque converter must be held to the torque converterhousing by a retaining device such as shipping...
Holding Fixture Installation Automatic      Special Tools J-8763-BHolding Fixture and Base For equivalent regional tools, refer toSpecial Tools. 8763b Install theJ-8763-Bholding fixture and baseonto the transmission.Install theJ-8763-Bholding fixture and baseinto...
Holding Fixture Removal and Torque Dampener Installation Automatic      Holding Fixture Removal and Torque Dampener Installation Callout Component Name 1 A/Trans Torque Dampener Assembly Special Tools J 21366 Converter Holding Strap 2 A/Trans Case Assembly Special...
Holding Fixture Removal Automatic      Special Tools J-8763-BHolding Fixture and Base 8763b Remove the transmission from theJ-8763-Bholding fixture.
Holding Fixture Removal Automatic      Warning:The 1000 Series™ transmission dry weight isapproximately 150-kg-(330-lb). Tohelp avoid personal injury and/or property damage: Use caution wheninstalling, removing, or moving the transmission. Get help whenlifting...
Hybrid Direct 2-3-4 Clutch Housing Overhaul Automatic Transmission Unit Automatic Clutches      Table 1: 2–3–4 Clutch Plates Disassemble Table 2: 2–3–4 Clutch Disassemble Table 3: 2–3–4 Clutch Assemble Table 4: 2–3–4 Clutch Plates Assemble 2–3–4 Clutch Plates Disassemble 2–3–4 Clutch Plates...
Hybrid Direct 2-3-4 Clutch Support Installation Automatic Transmission Unit Automatic Clutches      Hybrid Direct, 2-3-4 Clutch Support Installation Callout Component Name 1 Hybrid Direct, 2-3-4 Clutch SupportGasket 2 Hybrid Direct, 2-3-4 Clutch SupportAssembly 3 Hybrid Direct, 2-3-4 Clutch...
Hybrid Direct 2-3-4 Clutch Support Removal Automatic Transmission Unit Automatic Clutches      Hybrid Direct, 2-3-4 Clutch Support Removal Callout Component Name 1 Hybrid Direct, 2-3-4 Clutch HousingSeal Ring 2 Hybrid Direct, 2-3-4 Clutch SupportBolt-M6-x-1.0-x-20(Qty:-9) Special Tools DT-48784E8...
Hybrid Low 1-2 Clutch Piston Removal Automatic      Hybrid Low, 1-2 Clutch Piston Removal Callout Component Name 1 Hybrid Low, 1-2 Clutch Piston Retaining Ring Note:Do not reuse the retaining ring. 2 Hybrid Low, 1-2 Clutch Backing Plate Assembly 3...
Input Carrier Assembly and 2-6 Clutch Installation Automatic      Special ToolsJ 24204-2 Bar and Stud AssemblyJ 36850 Transjel® LubricantJ 44530 Clutch Piston Spring Compressor For equivalent regional tools, refer toSpecial Tools. Position the transmission case so that the rear of the...
Input Carrier Assembly Assemble Automatic      Position the intermediate internal gear-(4) on thework table so that the tang holes are facing up.Install the input carrier assembly-(3) into theintermediate internal gear-(4). Make sure the splinesare engaged.Install the...
Input Carrier Assembly Disassemble Automatic      Remove the thrust washer-(1) from the intermediateinternal gear-(4).Remove the retaining ring-(2) from theintermediate internal gear-(4).Separate the input carrier assembly-(3) from theintermediate internal gear-(4).
Input Carrier Assembly Inspection Automatic      Check the end play between the input carrier-(1)and the thrust washer-(2) at each piniongear-(3).Replace the input carrier assembly if the end play exceedsspecifications. Specification Replace the input carrier assembly if...
Input Carrier Bushing Replacement Automatic      Tools RequiredGE-8092 Driver HandleJ 43781 Input Carrier Bushing Remover/Installer Important:The preferred method for removing/installing the input carrier bushing is to useJ 43781 input carrier bushing remover/installer...
Input Carrier Inspection and Installation Automatic      Special ToolsJ-29837-AOutput Shaft Support FixtureJ-36850Transjel Lubricant 662 Inspect the input carrier captive thrust bearing assembly. Tocheck the captive thrust bearing in the input carrier (662) forwear, place a...
Input Carrier Inspection Automatic      Important:Check end play on each pinion. Check the input carrier pinion end play. The end play mustnot exceed 0.61-mm (0.024-in).Inspect the input carrier for pinion gear damage, proper pinstake and keystoned pinion gears....
Input Carrier Removal Automatic      Remove the input carrier assembly-(2). Important:The thrust bearing assembly may stick to the input carrierassembly or the intermediate carrier assembly. Remove thrust bearing assembly-(1) from inputcarrier assembly-(2) or...
Input Clutch Assembly Disassemble Automatic Transmission Unit Automatic Clutches      Special ToolsJ-23327-1Forward Clutch SpringCompressor-(Bridge)J-23456Booster and Clutch Pack CompressorJ-25018-AClutch Spring Compressor Adapter Remove the reverse input clutch housing and drumassembly-(605) from the input...
Input Housing to Output Shaft Seal Installation Automatic      Install a new input housing to output shaft seal(636).
Input Internal Ring Gear Inspection Automatic      Important:Clutch plate movement can cause notching on the externalsplines of the input internal ring gear. Inspect the external splines of the input internal ringgear-(1) for notching.Replace the ring gear if detectable...
Input Shaft and Components Manual      Input Shaft and Components (1) Bearing Retainer Spacer (2) Tapered Bearing Race (3) Bearing Taper and Rollers (4) Input Shaft (5) Input Shaft Guide Rollers (6) Clutch Ring (7) 3rd/4th/5th Gear...
Input Shaft Fluid Seal Ring Installation Automatic      Special ToolsJ-36418-1BTurbine Shaft Seal InstallerJ-36418-2ATurbine Shaft Seal Sizer Use theJ-36418-1Bseal installer-(1) in order to install the four turbine shaftoil seal rings (619).Resize oil seal rings-(619)...
Input Shaft Front and Rear Bushing Replacement Automatic      Special ToolsJ-7004-AUniversal RemoverJ-8092Universal DriverHandle-–-3/4-in-–-10J-21465-01Bushing Service SetJ-25019-14Bushing InstallerJ-34196-BTransmission Bushing Service SetRemoval Procedure Inspect the pump cover, all...
Input Shaft Installation Automatic      Input Shaft Installation Callout Component Name 1 Internal Gear Retaining Ring-–- 1st Position Note:Use a NEW retaining ring. Do not reuse the old retaining ring. 2 Input Shaft 3 Internal Gear-–-...
Input Shaft Sun Gear Carrier and Sun Gear Removal Automatic      Input Shaft, Sun Gear Carrier, and Sun Gear Removal Callout Component Name 1 Input Shaft Thrust Bearing 2 Input Shaft Assembly 3 Sun Gear Carrier Thrust Bearing-–-1st Position 4 Internal...
Input Sun Gear Bushing Replacement Automatic      Special ToolsJ-8092Universal DriverHandle-–-3/4-in-–-10J-34196-BTransmission Bushing Service SetRemoval Procedure Using J 34196-5 which is part of kitJ-34196-Bbushing service setwithJ-8092driver handle, remove the input sun...
Intermediate Carrier and Main Shaft Removal Automatic      Remove, as a unit, the main shaft-(3), theintermediate sun gear-(2), and the sun gearspacer-(1).Remove the sun gear spacer-(1) and theintermediate sun gear-(2) from the main shaft. Remove the intermediate...
Intermediate Carrier Assembly and Main Shaft Installation Automatic      Special Tools J 44587Main Shaft Holder For equivalent regional tools, refer toSpecial Tools. Install the intermediate carriermodule-(2).Rotate the intermediate carrier module-(2) untilthe module drops into place....
Intermediate Carrier Assembly Assemble Automatic      Position the output carrier internal gear-(3) onthe work table so that the outer splines are facing down.Install the intermediate carrier assembly-(2) intothe output carrier internal gear-(3). Make sure thesplines are...
Intermediate Carrier Assembly Disassemble Automatic      Remove the retaining ring-(1) from the outputcarrier internal gear-(3).Separate the intermediate carrier assembly-(2)from the output carrier internal gear-(3).
Intermediate Carrier Assembly Inspection Automatic      Check the end play between the intermediate carrierassembly-(1) and the thrust washer-(2) ateach pinion gear-(3).If the end play exceeds specifications replace theintermediate carrier assembly. Specification The maximum end...
Intermediate Carrier Bushing Replacement Automatic      Tools RequiredGE-8092 Driver HandleJ 43785 Intermediate Bushing Remover/Installer Important:The preferred method for removing/installing the intermediate carrier bushing is touse J 43785 intermediate bushing remover/installer...
Intermediate Internal Gear Inspection Automatic      Important:Clutch plate movement can cause notching on the externalsplines of the intermediate internal gear. Inspect the external splines of the intermediate internalgear.Replace the intermediate internal gear if detectable...
Internal Transmission Speed Sensor Rotor Replacement Automatic Transmission Unit      Special ToolsJ-8433Two Jaw PullerJ-21427-ASpeedometer Gear Puller AdapterJ-36352Speed Sensor Rotor Installer KitRemoval Procedure Inspect the internal transmission speed sensorrotor-(699) for cracks or damaged teeth.Inspect...
Locking Differential Clutch Disc Assembly Disassemble (11 5 Inch Axle) Manual Clutch Friction Material      Remove the guide clips (3).Remove the clutch discs and the splined discs (2,4–7) from the side gear (1).
Locking Differential Clutch Disc Assembly Disassemble (10 5 Inch Axle) Manual Clutch Friction Material      Remove the guide clips-(6).Remove the clutch discs and the splineddiscs-(2–5, 7) from the locking differentialside gear-(1).
Locking Differential Clutch Disc Assembly Disassemble (9 5 Inch Axle) Manual Clutch Friction Material      Remove the guide clips-(2).Remove the clutch discs and the splineddiscs-(3–7) from the locking differential sidegear-(1).
Locking Differential Clutch Disc Assembly Assemble (9 5LD Axle) Manual Clutch Friction Material      Apply proper axle lubricant to the surface of each disc.Refer toAdhesives, Fluids, Lubricants, and Sealers.Assemble the right side or bell-end side clutch disc assemblyas follows:Install the 1st non-carbon eared disc-(3) to...
Locking Differential Clutch Disc Assembly Assemble (11 5 Inch Axle) Manual Clutch Friction Material      Apply axle lubricant, GM-P/N-12378261(Canadian-P/N-10953455) or equivalent meetingGM-Specification-9986115, to the surface ofeach disc.Assemble the right side or bell-end side clutch disc assemblyas follows:Install the 1st...
Locking Differential Clutch Disc Assembly Assemble (10 5) Manual Clutch Friction Material      Apply the proper axle lubricant to the surface of each disc.Refer toAdhesives, Fluids, Lubricants, and Sealers.Assemble the left side clutch disc assembly asfollows:Install the 1st non-carbon eared disc-(2) to theside...
Low and Reverse Clutch Backing Plate Inspection Automatic Transmission Unit Automatic Clutches      Important:Perform the following measurements at 3 or morelocations. Measure the thickness of each low and reverse clutch backingplate-(1) at dimension A. Specification The low and reverse clutch backing plate minimum...
Low and Reverse Clutch Backing Plate Retaining Ring Measurement Automatic Transmission Unit Automatic Clutches      Low and Reverse Clutch Backing Plate Retaining Ring Measurement Callout Component Name Preliminary ProceduresInstall DT-47868-1 pack travel weight and DT-47868-4 travel weight adapter onto the low and reverse clutch...
Low and Reverse Clutch Housing Assembly Disassemble Automatic Transmission Unit Automatic Clutches      Note:The low and reverse clutch housing, 2WD and the low andreverse clutch housing, 4WD are disassembled using the sameprocedures except as indicated. Remove the retaining ring-(1). To remove the output carrier support...
Low and Reverse Clutch Housing Assembly Assemble Automatic Transmission Unit Automatic Clutches      Tools Required J 36850 Transjel® Lubricant Position the low and reverse clutch housing so that the outside of the housing isfacing down. Important:The low and reverse clutch housing, 4WD does not contain an output speed...
Low and Reverse Clutch Housing Retaining Ring Replacement Automatic Transmission Unit Automatic Clutches      Important:DO NOT replace the retaining ring in the low and reverseclutch housing unless: The retaining ring is damaged.The low and reverse clutch housing is to be replaced.Position the low and reverse clutch housing-(2)...
Low and Reverse Clutch Installation Automatic Transmission Unit Automatic Clutches      Starting with a low and reverse clutch fiber plate,alternately install 6 low and reverse clutch fiberplates-(2) and 5 low and reverse clutch steelplates-(3).Install the correct selective low and reverse clutch steelplate-(1).
Low and Reverse Clutch Overhaul Automatic Transmission Unit Automatic Clutches      Table 1: Low and Reverse Clutch Plate Removal Table 2: Low and Reverse Clutch Piston Removal Table 3: Low and Reverse Clutch Piston Installation Table 4: Low and Reverse Clutch Plate Installation Low and...
Low and Reverse Clutch Piston and Output Carrier Assembly Removal Automatic Transmission Unit Automatic Clutches      Caution:Refer toTorque Converter Housing/Low and Reverse Clutch Housing Bolt Size Caution. Note:Remove the low and reverse clutch housing – 4WD using the same procedure as when removinga low and reverse clutch housing –...
Low and Reverse Clutch Piston Housing Installation Automatic Transmission Unit Automatic Clutches      Note:Except as noted, a low and reverse clutch housing, 4WD isinstalled using the same procedures as used when installing a lowand reverse clutch housing, 2WD. Install a new gasket-(2) onto the transmissioncase-(3).For a...
Low and Reverse Clutch Piston Installation Automatic Transmission Unit Automatic Clutches      Special ToolsJ-23327-1Forward Clutch SpringCompressor-(Bridge)J-34627Snap Ring Remover and InstallerJ-36850Transjel Lubricant 695 696 Install the transmission (low and reverse clutch outer,center, inner) seals (696) on the...
Low and Reverse Clutch Piston Removal Automatic Transmission Unit Automatic Clutches      Special ToolsJ-23327-1Forward Clutch SpringCompressor-(Bridge)J-34627Snap Ring Remover and InstallerJ-42628Plate 42628 Install theJ-23327-1compressor-(bridge)and theJ-42628plate. 23327 Tighten...
Low and Reverse Clutch Plate Inspection Automatic Transmission Unit Automatic Clutches      Important: Perform the following measurements at 3 or morelocations.Check the plates for coning on a level surface.Replace any parts not meeting specifications.Measure the thickness of each low and reverse clutch...
Low and Reverse Clutch Plate Installation Automatic Transmission Unit Automatic Clutches      Install the waved plate.Install the correct selective spacer plate (from theselection procedure).Install the five fiber plate assemblies and four steelplates, starting with one fiber plate assembly and alternating...
Low and Reverse Clutch Plate Reaction Carrier and Output Shaft Removal Automatic Transmission Unit Automatic Clutches      Special Tools J-29837-AOutput Shaft Support Fixture Remove the reaction sun gear (673) and the thrust washer(674). Remove the low and reverse support retainer ring(676). Remove theJ-29837-Asupport fixture. Push...
Main Shaft and Components Manual      Main Shaft and Components (1) 1st/2nd and 3rd/4th GearSynchronization Insert (2) Synchronization Spring (3) 3rd–4th GearSynchronization Hub (4) 3rd–4th GearSynchronization Collar (5) 3rd/4th/5th Gear...
Main Shaft and Counter Gear Shaft Axial Play Measurement Manual      Install the axial bearing. Install the input shaft thrust bearing. Install the input shaft synchronizer ring. Install the input shaft. Install the primary shaft arrangement. Inspect the axial play of the...
Main Shaft Assemble Manual      Place the main shaft on a workbench. away Install the 2nd speed gear roller cage. Using a press or driving tool, adjust 2nd speed gear and 3rdspeed bushing. Install the 2nd speed gear inner ring. Install the 2nd...
Main Shaft Assemble Manual      Use a flange or other tool to position the main shaftassembly vertically. Install the reverse clutch taper. Using locking pliers, position the clutch taper snapring. Install the lubricated reverse gear synchronizer...
Main Shaft Cleaning and Inspection Automatic      Important:Replace the main shaft if the specifications are notmet. Inspect the main shaft pilots for damage.Measure the main shaft pilots at dimension A. Specification The main shaft pilot minimum outside diameter...
Main Shaft Disassemble Manual      Remove the primary shaft from the transmission. Place the primary shaft on a workbench. Using a screwdriver, remove the drive wheel. Using retainer pliers, remove the drum retainer. Remove the 3rd and 4th...
Main Shaft Disassemble Manual      Use a flange or some other type of tool to place the assemblyin a vertical position. Remove the clutch bearing from the drive shaft and thesynchronizer ring. Remove the pulleys, the track, and the push bearing. cv...
Main Shaft Input Shaft and Components Manual      Main Shaft, Input Shaft, and Components (1) Counter Gear Bearing Shim (2) Input Shaft BearingAssembly (3) Input Shaft Bearing (4) Input Shaft Bearing (5) Input Shaft (6) Main Shaft Bearing Roller...
Main Shaft Installation Automatic      Main Shaft Installation Callout Component Name 1 Main Shaft Assembly 2 Internal Gear Thrust BearingAssembly-–-2nd Position
Main Shaft Rear Seal Replacement Manual      Tools RequiredJ 23129 Universal Seal RemoverJ 6125-1B Slide HammerJ 36503 Extension Housing Seal InstallerRemoval Procedure Remove the rear propeller shaft. Refer toOne-Piece Propeller Shaft ReplacementorTwo-Piece Propeller...
Main Valve Body Disassemble Automatic Transmission Unit Control Valve Body      Special ToolsJ-33163Valve Tray SetJ-43773Valve Spring Compressor For equivalent regional tools, refer toSpecial Tools. Note:To prevent confusing parts during assembly, useJ-33163valve tray setto store the removed valves,...
Manual Detent Spring Installation Automatic      Inspect the manual detent spring assembly-(63) forcracks or damage.Install the manual detent springassembly-(63). Caution:Refer toFastener Caution. Install the manual detent spring bolt-(64).Tighten the bolt...
Manual First Gear Automatic      A manual 2-1 downshift can be accomplished by moving the gearselector lever into the manual first (1) position when thetransmission is operating in second gear. The downshift to firstgear is controlled electronically by the...
Manual Second Gear Automatic      A manual 3-2 downshift can be accomplished by moving the gearselector lever into the Manual Second (2) position when thetransmission is operating in third gear. This causes thetransmission to shift immediately into second gear...
Manual Shift Detent Lever and Park Pawl Actuator Replacement Automatic      Manual Shift Detent Lever and Park Pawl Actuator Replacement Callout Component Name Preliminary Procedure Remove the valve body. Refer toControl Valve Lower Body and Upper Body Replacement. 1 Manual Shaft...
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Installation Automatic      87 Install the parking lock bracket (86). Caution:Refer toFastener Caution. Install the parking lock bracket bolt (87) and tighten to31-Y(23-lb-ft).Inspect the following items:The parking brake pawl (81) for damage or...
Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Automatic      Removal ProcedureRemove the transmission oil pan and filter. Refer toAutomatic Transmission Fluid and Filter Replacement. Remove the shift lever nut and shift lever. Remove the manual detent spring bolt-(64).Remove the...
Manual Shift Detent Lever with Shaft Position Switch Assembly and Park Pawl Actuator Removal Automatic      Remove the following parts:Manual valve link-(89)Manual shift detent lever hub pin-(92) discard, donot reuseManual shift detent lever with shaft position switchassembly-(88)Parking lock actuator assembly-(85)Manual shaft...
Manual Shift Shaft and Parking System Components Overhaul (6L80 6L90) Automatic      Manual Shift Shaft and Parking System Components Overhaul Callout Component Name 1 Manual Shaft Detent Lever Hub Pin Caution:Refer toPin Reuse Caution. 2 Manual Shift Shaft Pin Caution:Refer toPin Reuse...
Manual Shift Shaft and Seal Replacement Automatic      Manual Shift Shaft and Seal Replacement Callout Component Name Preliminary ProceduresRaise and support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the transmission fluid pan. Refer toAutomatic...
Manual Shift Shaft Detent Lever and Position Switch Assembly Disassemble Automatic      Special Tools J 43909Manual Shift Shaft Seal Remover For equivalent regional tools, refer toSpecial Tools. Note:Do not remove the manual shift shaft unless replacing one ormore of the following: Manual shift shaftDetent...
Manual Shift Shaft Detent Lever and Position Switch Assembly Replacement Automatic      Removal Procedure Remove the control valve assembly from the transmission.Refer toControl Valve Body Replacement. Note:The detent lever/IMS retaining bolt contains patch lockmaterial on the threads. Do not reuse the...
Manual Shift Shaft Detent Lever and Position Switch Assembly Assemble Automatic      Special Tools J 43909Manual Shift Shaft Seal Installer For equivalent regional tools, refer toSpecial Tools. Install a new manual shift shaft seal-(1) ontoJ 43909installer-(2).UsingJ 43909installer-(2) , drive the manual...
Manual Shift Shaft Position Switch Overhaul Automatic      Manual Shift Shaft Position Switch Overhaul Callout Component Name 1 A/Trans Manual Shift Shaft Position SwitchBolt-M5-x0.8-x-20 Caution:Refer toPin Reuse Caution. Caution:Refer toFastener Caution. Tighten...
Manual Shift Shaft Position Switch Replacement Automatic      Manual Shift Shaft Position Switch Replacement Callout Component Name Preliminary ProceduresRaise and support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the transmission fluid pan and filter. Refer...
Manual Shift Shaft Position Switch Replacement Automatic      Manual Shift Shaft Position Switch Replacement Callout Component Name Preliminary ProceduresRemove the transmission range select lever. Refer toAutomatic Transmission Range Selector Lever Replacement.Remove the...
Manual Shift Shaft Seal Installation Automatic      Install a new manual shaft seal (82).
Manual Shift Shaft Seal Replacement Automatic      Manual Shift Shaft Seal Replacement Callout Component Name Preliminary Procedure Remove the manual shift shaft position switch. Refer toManual Shift Shaft Position Switch Replacement. 1 Manual Shift Shaft...
Manual Shift Shaft Seal Replacement Automatic      Manual Shift Shaft Seal Replacement Callout Component Name 1 Manual Shift Shaft Seal Caution:Do not damage the case bore during removal of the manualshift shaft seal. Caution:When installing the seal, ensure the...
Manual Shift Shaft Seal Replacement Automatic      Special ToolsJ 43911Selector Shaft Seal RemoverJ 43909Selector Shaft Seal InstallerRemoval Procedure Disconnect the range selector lever cable and lever from the manual shaft.Ensure that the jackscrew forJ 43911selector...
Manual Shift Shaft Seal Replacement Automatic      Manual Shift Shaft Seal Replacement Callout Component Procedure 1 Manual Shift Shaft Seal Caution:Do not damage the case bore during removal of the manualshift shaft seal. Caution:When installing the seal,...
Manual Shift Shaft Seal Replacement Automatic      Tools RequiredJ 43911 Manual Shift Shaft Seal RemoverJ 43909 Manual Shift Shaft Seal InstallerRemoval Procedure Be sure that the jackscrew for J 43911 manual shift shaft seal remover is backed off and will not interfere...
Manual Third Gear Automatic      A manual 4-3 downshift is available to increase vehicleperformance when the use of only three gear ratios is desired.Manual Third gear range also provides engine braking in Third gearwhen the throttle is released. A manual 4-3...
Manual Transmission Description and Operation Manual      (1) Transmission Model (2) Transmission Number (3) Assembly Date (4) Series Number Important:All TR-3450 transmissions are identified by amodel number and a series number, as well as a manufacture...
Manual Transmission Description and Operation Manual      TR-4050 Series transmissions have an advanceddesign with 5-synchronized forward gears and1-synchronized reverse gear. This design offers a moreefficient ratio of torque-weight than any other5-speed transmission in its class....
Nameplate Figure Transmission Identification Information Automatic      Nameplate Components (1) Date of Manufacture (2) Transmission IdentificationNumber (3) Engineering Feature ConfigurationNumber (4) Serial Number
Oil Pump Locating Pin Replacement Automatic      Special Tools J 43779Locating Pin Installer For equivalent regional tools, refer toSpecial Tools. Note:Do not replace the oil pump locating pin or pins unless thepin or pins are damaged. Remove the locating pin-(2) from...
Oil Pump Removal Automatic      Special Tools J-45053Universal Clamp Press Remove all pump bolts-(2) and pump boltseal-(3).InstallJ-45053clamp pressover stator shaft. Tighten the clampbolts-(1).To prevent slipping, securely fasten theJ-45053clamp...
Output Carrier Assembly Overhaul (6L90) Automatic      Output Carrier Assembly Overhaul Callout Component Name 1 Output Carrier Front Sun Gear Thrust Bearing Assembly 2 Center Support Roller Bearing Caution:Do not reuse the center support roller bearing....
Output Carrier Inspection Automatic      Measure the end play between the outputcarrier-(1) and the thrust washer-(2) at eachpinion gear-(3).Replace the output carrier assembly if the end play exceedsspecifications. Specification The maximum pinion end play is...
Output Carrier Internal Gear Inspection Automatic      Important: Clutch plate movement can cause notching on the externalsplines if the output carrier internal gear.Replace the output carrier internal gear if thespecifications are not met.Inspect the external splines of the...
Output Carrier to Output Internal Gear Assemble (6L80 6L90) Automatic      Output Carrier to Output Internal Gear Assemble Callout Component Name Note:This procedure only applies to the second design output shaft assembly (output internalgear assembly). If you have a first design output...
Output Carrier to Output Shaft Assemble (6L80 6L90) Automatic      Output Carrier to Output Shaft Assemble Callout Component Name 1 Output Carrier Thrust Bearing Assembly 2 Output Carrier Internal Front Gear Caution:Install the gear flat side down. Failure to install the...
Output Internal Gear Disassemble (6L80 6L90) Automatic      Output Internal Gear Disassemble Callout Component Name Note:This procedure only applies to the second design output shaft assembly (output internalgear assembly). If you are disassembling a first design out shaft...
Output Shaft and Output Carrier Assembly Installation Automatic      Install the output shaft-(2) into the outputcarrier assembly-(1).While holding the output shaft-(2), place theoutput carrier assembly-(1) into the top of the outputring gear-(3).Move/rotate the output shaft until the...
Output Shaft Assemble (6L80 6L90) Automatic      Output Shaft Assemble Callout Component Name Note:This procedure only applies to the first design output shaft assembly. If you havea second design output shaft assembly (output internal gear assembly), refer...
Output Shaft Bushing Replacement Automatic      Tools RequiredJ 43791 Output/Turbine Shaft Bushing InstallerJ 44526 Output/Turbine Shaft Bushing RemoverRemoval Procedure Install J 44526-2 bolt-(8) and J 44526-1 extractor-(7) into the bushing-(9) .Install J 44526-2...
Output Shaft Disassemble (6L80 6L90) Automatic      Output Shaft Disassemble Callout Component Name Note:This procedure only applies to the first design output shaft assembly. If you aredisassembling a second design output shaft assembly (output internal gear...
Output Shaft Installation Automatic      Special Tools J-29837-AOutput Shaft Support Fixture Note:It is important to note that the input shaft may need a lighttap to fully seat into position. If the input shaft is notcompletely engaged, the output shaft to input...
Output Shaft Seal Replacement Automatic      Output Shaft Seal Replacement Callout Component Name Preliminary Procedure Remove the rear propeller shaft. Refer toOne-Piece Propeller Shaft Replacement. 1 Propeller Shaft Front Slip Yoke Seal Special...
Output Shaft Seal Replacement (AWD Models Only) Automatic      Output Shaft Seal Replacement Callout Component Name 1 Output Shaft Seal Assembly Caution:Refer toSeal Reuse Caution. Special ToolEN 37212Front Output Shaft SealInstaller-(6L50)DT 38693Seal Installer-(6L80)EN...
Output Shaft Thrust Bearing Race Replacement Automatic      Special ToolsJ 44528Output Carrier Bearing Race RemoverJ 43797Output Carrier Bearing Race Installer For equivalent regional tools, refer toSpecial Tools. Removal Procedure Position the output carrier assembly-(2) on thework...
Output Yoke Inspection Automatic      Important: Measure as described below at 3 or more locations.Replace the output yoke if the specifications are notmet.Inspect the output yoke-(1) for damage.Measure the outside diameter-(OD) of the outputyoke oil seal...
Overdrive Range 3-2 Downshift Automatic      Similar to a forced 4-3 downshift, a forced 3-2 downshift canoccur because of minimum throttle (coastdown conditions), heavythrottle or increased engine load. In order to achieve a forced 3-2downshift, the PCM energizes the...
Overdrive Range 4-3 Downshift Automatic      When the transmission is operating in fourth gear, a forced4-3 downshift occurs if there is a significant increase in throttleposition. At minimum throttle, the vehicle speed decreasesgradually (coastdown) and the PCM commands...
Overdrive Range First Gear Automatic      When the gear selector lever is moved to the Overdriveposition, from the neutral position, the following changes occur tothe transmission's hydraulic and electrical systems: Manual Valve Line pressure flows through the manual...
Overdrive Range Fourth Gear - Torque Converter Clutch Applied Automatic Torque Converter Torque Converter Clutch and Lockup - part 2      This fluid pressure, inaddition to spring force and torque signal fluid pressure,regulates the exhaust of excess accumulator fluid pressure throughthe middle of the valve. This regulation helps control the 2-4 bandapply feel....
Overdrive Range Fourth Gear - Torque Converter Clutch Applied Automatic Torque Converter Torque Converter Clutch and Lockup      At higher vehicle speeds, the Hydra-matic 4L60-E transmissionuses an overdrive gear ratio (fourth gear) in order to increasefuel economy and in order to maximize engine performance. Whenvehicle operating conditions are...
Overdrive Range Second Gear Automatic      As vehicle speed increases and other operating conditions areappropriate, the PCM de-energizes the 1-2 shift solenoid valve inorder to shift the transmission to second gear. 1-2 Shift Solenoid (SS) Valve De-energized (turned...
Overdrive Range Third Gear Automatic      As vehicle speed increases further and other vehicleoperating conditions are appropriate, the PCM de-energizes thenormally open 2-3 shift solenoid valve in order to shift thetransmission into Third gear. 2-3 Shift Solenoid...
Overrun Clutch Installation Automatic      Inspect the fiber plate assemblies (645B) and the steelplates (645A) for the following defects:Damaged tangsDelaminationExcessive wearWear or heat damage Install the overrun clutch plates into the input housingstarting...
Park Pawl and Actuator Replacement Automatic      Park Pawl and Actuator Replacement Callout Component Name Preliminary ProceduresRemove the manual shift shaft position switch. Refer toManual Shift Shaft Position Switch Replacement.Remove the rear case. Refer toRear...
Park Pawl Cover and Gasket Replacement Automatic      Park Pawl Cover and Gasket Replacement Callout Component Name Caution:Use Dexron-VI transmission fluid only. Failure touse the proper fluid may result in transmission internaldamage. Preliminary ProceduresRaise and...
Park Pawl Installation Automatic      Align the tang in the low and reverse clutch return springassembly-(1) with the notch in the transmissioncase.Install the low and reverse clutch piston return springassembly-(1).Install the park pawl cam guide-(3).Install...
Park Pawl Replacement Automatic      Table 1: Removal Table 2: Installation Removal Removal Callout Component Name 1 Park Pawl Cover Bolt-M6-x-1.0-x-20 (Qty:-5) 2 Park Pawl Cover 3 Park Pawl Cover Gasket 4 Park...
PI0488C Diagnostic Information for Transmission No Forward No Reverse Slips Cracked Split Fluid Filter - (May 7 2013) Automatic Transmission Unit      Subject: Diagnostic Information for Transmission No Forward, No Reverse, Slips, Cracked/SplitFluid Filter Models:  2010-2013 Cadillac CTS-V, Escalade Models 2010-2013 Chevrolet Avalanche 2010-2013 Chevrolet...
PI0522D Tick Buzz or Rattle Noise from Front of Dash Transmission Filler Tube Cracked or Broken - (Mar 5 2013) Automatic Transmission Unit - part 2      A damaged transmission filler tube will likelycrack during this inspection.If the transmission filler tube is not damaged, proceed to Step 6.If the transmission filler tube is damaged, replace the transmission filler tube.Refer...
PI0522D Tick Buzz or Rattle Noise from Front of Dash Transmission Filler Tube Cracked or Broken - (Mar 5 2013) Automatic Transmission Unit      Subject: Tick, Buzz or Rattle Noise from Front of Dash, Transmission Filler Tube Cracked orBroken Models:  2007-2013 Cadillac Escalade Models (excluding Hybrids) 2007-2013 Chevrolet Avalanche, Silverado,...
PI0531B Transmission Over Temperature Malfunction Indicator Lamp (MIL) Illuminated DTC U0101 Set (Inspect Transmission Cooler Lines) - (Jul 10 2013) Automatic ATF Lines      Subject: Transmission Over Temperature, Malfunction Indicator Lamp (MIL) Illuminated, DTC U0101Set (Inspect Transmission Cooler Lines) Models:  2011-2013 Chevrolet Silverado 2011-2013 GMC Sierra Equipped...
PIP3136Q Slip Condition In 2nd 3rd Or 4th - Damaged 2-4 Band Or 3-4 Clutch - (Aug 1 2012) Automatic Transmission Unit Trans Bands Brakes - part 2      The turbine shaft (621) may also be damaged in the stator bushing journalarea. This condition may be caused by the stator shaft (214) being non-concentric with thepump cover (215). If this condition is encountered the pump...
PIP3136Q Slip Condition In 2nd 3rd Or 4th - Damaged 2-4 Band Or 3-4 Clutch - (Aug 1 2012) Automatic Transmission Unit Trans Bands Brakes      Subject: Slip Condition In 2nd 3rd Or 4th - Damaged 2-4 Band Or 3-4 Clutch Models:  2004 - 2007 Buick Rainier 2003 - 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2003 - 2005 Chevrolet Astro, Blazer,...
PIP4600C TAC 2ML70 (Two-Mode Hybrid) Transmission Restriction Process - (Dec 18 2012) Automatic Transmission Unit - part 3      arranty Information For vehicles repaired under warranty use: Labor Operation Description Labor Time K7000 Transmission Replacement Use Published Labor Operation Time Please follow this diagnostic or repair...
PIP4600C TAC 2ML70 (Two-Mode Hybrid) Transmission Restriction Process - (Dec 18 2012) Automatic Transmission Unit - part 2      Please have as muchstored DTC and snapshot information as possible prior to contacting TAC.After reviewing the diagnosis, if transmission replacement is needed, TAC will arrangefor ordering of a new assembly.For return of...
PIP4600C TAC 2ML70 (Two-Mode Hybrid) Transmission Restriction Process - (Dec 18 2012) Automatic Transmission Unit      Subject: TAC 2ML70 (Two-Mode Hybrid) Transmission Restriction Process Models:  2009-2013 Cadillac Escalade 2009-2013 Chevrolet Silverado 2008-2013 Chevrolet Tahoe 2009-2013 GMC Sierra 2008-2013 GMC...
PIP4793G PQC Restriction Allison A1000 Transmission Valve Body RPO MW7 - (Jun 27 2013) Automatic Transmission Unit Control Valve Body      Subject: PQC Restriction Allison A1000 Transmission Valve Body RPO MW7 Models:  2012-2014 Chevrolet Silverado 2012-2014 GMC Sierra, Sierra Denali Equipped with Allison A1000 Transmission RPO MW7 This PI...
PIP4833D Auxiliary Transmission Fluid Pump (ATFP) Control Module And Pump Parts Restriction - (Aug 8 2012) Automatic      Subject: Auxiliary Transmission Fluid Pump (ATFP) Control Module And Pump Parts Restriction Models:  2009-2013 Cadillac Escalade 2008-2013 Chevrolet Tahoe 2009-2013 Chevrolet Silverado 2009-2013 GMC...
PIP5021B PQC 2012 to 2014 Allison A1000 Automatic Transmission Assembly Restriction - (Jun 27 2013) Automatic      Subject: PQC 2012 to 2014 Allison A1000 Automatic Transmission Assembly Restriction Models:  2012-2014 Chevrolet Silverado 2012-2014 GMC Sierra Equipped With The Allison LCT1000 Transmission RPO MW7 This...
PIP5059 Whistle Or Whine Noise In 3rd Gear May Be More Pronounced On A Coast - (Sep 6 2012)      Subject: Whistle Or Whine Noise In 3rd Gear May Be More Pronounced On A Coast Models:  2010 - 2013 Chevrolet Colorado, Express, Silverado 2010 - 2013 GMC Canyon, Savana, Sierra Equipped with 4L60E (M30)...
PIP5065D Ticking Noise In 3rd And 4th Gear Above 30 MPH - (Feb 26 2013)      Subject: Ticking Noise In 3rd And 4th Gear Above 30 MPH Models:  2012  Chevrolet Colorado 2012-2013  Chevrolet Express, Silverado 2012  GMC Canyon 2012-2013  GMC Savana, Sierra Equipped with 4L60E...
PIT5206A Unwanted Grade Braking Low Power and or Transmission Busy Shifting - (Nov 14 2013) Automatic Transmission Unit      Subject: Unwanted Grade Braking, Low Power, and/or Transmission Busy Shifting Models:  2012-2014 Cadillac Escalade Models 2012-2013 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2014 Chevrolet Silverado...
Power Off High Default Automatic      If the transmission is in Third or Fourth gear during atransmission electrical component malfunction, the transmissionwill defualt to high. All solenoids will default to their normalstate. The transmission will remain in Power...
Power Off Low Default Automatic - part 2      Shift SolenoidValve-–-Mode-B Exhausting HD-234 clutch fluid pressure passesthrough the shift solenoidvalve-–-mode-B into theHD-234 clutch supply circuit. Shift SolenoidValve-–-Mode-A Shift solenoidvalve-–-mode-A springforce...
Power Off Low Default Automatic      If the transmission is in First or Second gear during atransmission electrical component malfunction, the transmissionwill defualt to Low. All solenoids will default to their normalstate. This default action enables the...
Pressure Control Solenoid Valve Replacement Automatic      Removal Procedure ml nu Remove the transmission oil pan and filter. Note:Do not remove the valve body for the following procedures.Removal of the 1-2 accumulator is necessary only if servicing thepressure control solenoid....
Pressure Control Solenoid Valve Replacement (Main MOD) Automatic      Removal Procedure Remove the oil pan and the transmission internal oil filter. Refer toOil Pan Replacement.Disconnect the internal wiring harness from the solenoid being changed.Remove the solenoid retainer-(4,5) for the...
Pressure Switch Manifold Replacement Automatic      Removal Procedure Note: Individual pressure switches cannot be replaced. When anypressure switch needs replacing, the entire assembly must bereplaced.The modulated main pressure-(MAIN MOD) solenoidhas been removed for...
Pump Body Fluid Passages (Pump Cover Side) Automatic      Pump Body Fluid Passages (Pump Cover Side) (1) Suction (intake) (2) Decrease (2) Decrease (3) Line (3) Line (3) Line (4) Converter Feed (4) Converter Feed (4) Converter Feed (5)...
Pump Cover Fluid Passages (Case Side) Automatic      Pump Cover Fluid Passages (Case Side) (1) Suction (Intake) (2) Decrease (2) Decrease (3) Line (3) Line (3) Line (5) Release (7) To Cooler (8) Lube from Cooler (8) Lube from Cooler...
Pump Cover Fluid Passages (Pump Body Side) Automatic      Pump Cover Fluid Passages (Pump Body Side) (1) Suction (intake) (1) Suction (intake) (2) Decrease (2) Decrease (2) Decrease (2) Decrease (3) Line (3) Line (3) Line (3) Line (3)...
Range Selector Lever Cable Adjustment Automatic "Shifter Input and Linkage"      Ensure that the steering column shift lever is in the park(P) position.Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Ensure that the transmission manual shaft lever is in thepark (P)...
Range Selector Lever Cable Bracket Replacement Automatic "Shifter Input and Linkage"      Range Selector Lever Cable Bracket Replacement Callout Component Name Preliminary ProceduresApply the park brake.Shift the transmission into neutral.Raise the vehicle. Refer toLifting and Jacking the Vehicle.Remove...
Range Selector Lever Cable Bracket Replacement Automatic "Shifter Input and Linkage"      Removal Procedure Apply the park brake.Shift the transmission into neutral.Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the retainer that secures the cable to the bracket.Depress...
Range Selector Lever Cable Replacement Automatic "Shifter Input and Linkage"      Removal Procedure Warning:The automatic transaxle range selector cable is made out oftwo cable sections. After initial connection never separate the twometal couplings from one another. Integrity of the connection ofthe two...
Reaction Carrier Shaft Replacement Automatic      Removal ProcedureTools RequiredJ 8092Universal Driver Handle-–-3/4-in-–-10J 7004-AUniversal RemoverJ 23907Slide Hammer with Bearing AdapterJ 25019-14Stator Pump Bushing RemoverJ 29369-2Bushing and Bearing Remover 2–3-inJ...
Reaction Gear and Carrier Inspection Automatic      Inspect the reaction carrier/support thrust bearing assembly(683) for wear or damage.Inspect the reaction gear support to case bearing (692) forwear or damage. Inspect the internal reaction gear (684) and the...
Reaction Gear and Carrier Installation Automatic      Special Tools J-36850Transjel Lubricant Install the reaction gear support to case bearing (692) ontothe internal reaction gear support (685). Retain the bearing usingJ-36850transjel lubricantor equivalent.Install the...
Reaction Sun Gear Installation Automatic      Special ToolsJ-34196-BTransmission Bushing Service SetJ-8092Driver Handle Note:Do not remove the retaining ring-(671), except toreplace it. Inspect the reaction sun gear-(673) for thefollowing defects:NicksScoresDamaged...
Reaction Sun Gear Shell Reaction Carrier Shaft Input Internal Gear and Input Carrier Assembly Removal Automatic      Important:The output shaft retainer ring-(661) can not bereused, it must be replaced. Use snap ring pliers to remove the output shaft retainerring-(661). Important:The carrier assembly-(662) can be a 4 or 5 piniondesign...
Reaction Sun Gear Shell Reaction Carrier Shaft and Input Internal Gear Assembly Installation Automatic      Special Tools J-36850Transjel Lubricant Install the reaction sun shell-(670) into thereaction sun gear.Install the thrust bearing-(669) usingJ-36850transjel lubricantonto the reaction carrier shaft, tangs up, toward...
Rear Ball Bearing Removal Automatic      Special ToolsDT-50689 Spanner Nut Wrench – 4WDJ-43910 Output Shaft Bearing Puller Leg SetJ-24420-B Universal Puller For equivalent regional tools, refer toSpecial Tools. Position the transmission so that the rear of the...
Rear Case and Gasket Replacement Automatic      Rear Case and Gasket Replacement Callout Component Name Caution:Use Dexron-VI transmission fluid only. Failure touse the proper fluid may result in transmission internaldamage. Preliminary ProceduresRemove the...
Rear Case Assembly - Case Assembly Side Automatic      Rear Case Assembly-–-CaseAssembly Side (6) B Cooling (18) HL 12 Clutch (30) HD 234 Clutch (41) Void
Rear Case Installation Automatic      Rear Case Installation Callout Component Name 1 A/Trans Rear Case Gasket Note:Verify that the sun gear-–-3rd position is on the sun gear shaft assembly-–-3rd position. 2 A/Trans Rear Case Assembly...
Rear Case Removal Automatic      Rear Case Removal Callout Component Name 1 A/Trans Rear Case Bolt-M8-x-1.25-x-30 (Qty:-12) 2 A/Trans Rear Case Assembly Note:During removal of the rear case, use care in order to retain the sun gear-–-3rd...
Rear Oil Seal Installation (2WD) Automatic      Tools Required J 43782 Rear Seal Installer Using J 43782 rear seal installer install the prop shaft front slip yoke oil seal-(1).Make sure the oil seal is installed to the correct depth below the rear face of thelow and...
Rear Output Shaft Bushing Replacement (Heavy Duty and Super Heavy Duty)      Rear Output Shaft Bushing Replacement Callout Component Name Preliminary Procedure Ensure the bushing is installed squarely into the bushing bore. 1 Transfer Case Rear Output Shaft Bushing Procedure Press...
Rear Output Shaft Cleaning and Inspection      Rear Output Shaft Cleaning and Inspection Callout Component Name Preliminary ProcedureInspect all components or sub-components and perform any repair procedure necessaryto fix the damage. If the damage cannot be...
Rear Output Shaft Seal Replacement      Special Tools J 45756 Output Shaft Seal Installer For equivalent regional tools, refer toSpecial Tools. Removal Procedure Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the...
Rear Output Shaft Seal Replacement      Rear Output Shaft Seal Replacement Callout Component Name Caution:Do not damage the sealing surfaces of the transfer cases orthe shafts when prying the seals for removal. Damaging the sealingsurface may cause leakage...
Release Bearing Replacement Manual Clutch Clutch Release Bearing      Removal Procedure Remove the transmission. Refer toTransmission Replacement.Remove the clutch release bearing.Rotate the bearing in either direction.The compression spring load will push the release bearing offthe end of...
Reverse Automatic      When the gear selector lever is moved to the Reverse (R)position (from the Park position), the following changes occur tothe transmissions hydraulic and electrical systems: Manual Valve The manual valve moves to the Reverse...
Reverse Automatic      When the manual selector valve is moved fromNeutral-(N) to Reverse-(R), shiftsolenoid-1-(SS1) de-energizes, turning OFFpressure switch-1. SS2 and SS3 remain energized, keepingpressure switch-2 and pressure switch-3 on.Reverse...
Reverse Automatic      When the gear selector lever is moved to the Reverse (R)position (from the Park position) the normally high C35R pressurecontrol solenoid 2 is commanded ON and the following changes occurin the transmission’s hydraulic and...
Reverse Idler Gear Disassemble Manual      Remove the 4th gear shaft from the case. Remove the 4-screws from the rear retainer. Remove the rear retainer and the adjuster shims. Remove the reverse shaft. Remove the reverse gear. Remove the 2-cages with...
Reverse Input and 3-4 Clutch Housing Installation Automatic Transmission Unit Automatic Clutches      Install the selective thrust washer-(616) on theinput housing-(621).Install the stator shaft/selective washer bearingassembly-(615) on the inputhousing-(621). The black race on the bearing goes toward the oilpump-–-facing...
Reverse Input Clutch Assemble Automatic Transmission Unit Automatic Clutches      Special ToolsJ-23327-1Forward Clutch SpringCompressor-(Bridge)J-25018-AClutch Spring Compressor AdapterJ-44571-1Reverse Input Clutch Piston Installer Inspect the reverse input clutch piston-(607) forthe following:Damaged or...
Reverse Input Clutch Disassemble Automatic Transmission Unit Automatic Clutches      Special ToolsJ-23327-1Forward Clutch SpringCompressor-(Bridge)J-25018-AClutch Spring Compressor Adapter Remove the reverse input clutch retaining ring (614).Remove all reverse input clutch plates(611–613). Install...
Reverse Input Clutch Housing Front and Rear Bushing Replacement Automatic Transmission Unit Automatic Clutches      Removal ProcedureSpecial ToolsJ-7004-AUniversal RemoverJ-8092Driver HandleJ-25019Bushing Service SetJ-34196-BTransmission Bushing Service Set Inspect the reverse input clutch housing and drum assemblyfor the following...
Reverse Input Clutch Plate Travel Check Automatic Transmission Unit Automatic Clutches      Apply an evenly distributed load to the clutch pack.Use feeler gauges to check the reverse input clutch platetravel.Check the travel between the selective backing plate and thereverse input clutch retainer ring. Clutch...
Second Range (Without TCC Applied) Automatic      Before shifting from first to second range, the transmissioncontrol module-(TCM) makes certain shiftvalve-1, shift valve-2, and shiftvalve-3 are in the correct position with shiftvalve-1 and shift valve-2 de-stroked andshift...
Shift Control and Components Manual      Shift Control and Components (1) Breather Connection (2) Control Cover Screws (3) Clip (4) Control Cover (5) Exhaust Tubing Support (6) Reverse Switch (7) Reverse Switch Gasket (8) Cap Guide...
Shift Control and Components Manual      Shift Control and Components (1) 1st and 2nd Shift Shaft (2) 1st and 2nd Shift BlockAssembly (3) Transmission Shift Fork PadInsert (4) 1st and 2nd Shift Block (5) 1st and 2nd Shift ForkAssembly (6)...
Shift Lever Replacement Transmission Shifter Mechanism      Removal ProcedureRemove the steering column shroud. Refer toSteering Column Shroud Replacement.Roll back the shift lever seal on the shift lever until theshift lever bolt is exposed.Disconnect any electrical connectors as...
Shift Shaft and Fork Assemblies Assemble Manual      Using a hammer, install the speed selector stop pin if it wasremoved. Install the shift lever. Using a hammer, install the 3rd and 4th fork. Using a hammer, install the fork retaining bolt on the 3rdand 4th shift...
Shift Shaft and Fork Assemblies Assemble Manual      If the fork leg inserts must be replaced, you should pressthem in. Ensure they are centered in the housing. Assemble the 1st and 2nd gear fork, if removed, using a NEWroll pin. If the fork leg inserts must be...
Shift Shaft and Fork Assemblies Disassemble Manual      Place the transmission on a workbench. Remove the 4-screws from the shift tower. Remove the shift tower. Remove the breather support screw. Using a 1/2 socket, remove the 10-screws from thecontrol cover. Lift...
Shift Shaft and Fork Assemblies Disassemble Manual      Using a hammer and a punch, remove the roll pin from the yokeand the reverse gearshift lever. Using a punch, turn the reverse gearshift lever to free itfrom the roll pin and remove. Remove the reverse fork. Remove...
Sixth Range Automatic - part 2      The 3rd,5th, and reverse clutch remains applied. With only one clutchapplied the transmission shifts to neutral If electrical power is interrupted while the transmission isin sixth range (causing fifth range converter...
Sixth Range Automatic      Before making a shift from fifth to sixth range, thetransmission control module-(TCM) makes certain that allshift valves are in the correct position. Shiftsolenoid-1-(SS1) and SS2 are electrically offand shift valve-1 and...
Spacer Plate Automatic      Spacer Plate (3) Line (9) Actuator Feed Limit (9/10) Actuator Feed Limit/FilteredActuator Feed (10) Filtered Actuator Feed (10/22) Filtered Actuator Feed/SignalA (10/23) Filtered Actuator Feed/SignalB...
Special Tools Automatic      Illustration Tool Number/Description DT-47694 Piston Spring Compressor DT-47715 Electrical Connector Passage Sleeve Remover/Installer DT-47770 Seal Installer DT-47820 Seal...
Special Tools Automatic      Illustration Tool Number/Description DT-49037 Mor Torq Bit J-7004-A Universal Remover J-8001 Dial Indicator Set J-8092 Driver Handle J-8433 Two Jaw Puller...
Special Tools Automatic      Illustration Tool Number/Description DT-3289-20 J-3289-20 Holding Fixture Base Assembly DT-8763-B J-8763-B Holding Fixture DT-21366 J-21366 Converter Holding Strap DT-23129...
Special Tools Automatic      Illustration Tool Number/ Description o00 o00 o00 o00 .. ooo Scan Tool DT-45096 Transmission Oil Cooling System Flush and Flow Test Tool DT-50689 Spanner Nut Wrench - 4WD J-5959...
Special Tools Manual      Illustration Tool Number/ Description J-23907 Slide Hammer with Bearing Adapter J-36502 Output Shaft Oil Seal Installer (4WD) J-36502-2A Output Shaft Oil Seal Protector (4WD)...
Special Tools Manual      Illustration Tool Number/Description J-23907 Slide Hammer with Bearing Adapter J-36825 Output Shaft Oil Seal Remover (4WD Models Only) J-42371 Hydraulic Clutch Line Separator
Stator Shaft Bushing Replacement Automatic Transmission Unit      Special ToolsJ 44529Stator Shaft Bushing RemoverJ 8092Universal DriverJ 43774Stator Shaft Bushing Installer For equivalent regional tools, refer toSpecial Tools. Caution:Always use J-44529 when removing the stator...
Stator Shaft Inspection Automatic Transmission Unit      Important: Replace the needle bearing if the bearing is damaged.The only time the stator shaft is pressed from the oil pumpcover assembly is to replace the stator shaft.The new stator shaft comes with a...
Stator Shaft Needle Bearing Replacement Automatic Transmission Unit      Special ToolsJ-26941Oil Pump Cover Needle Bearing RemoverJ-8092Universal DriverJ-43775Oil Pump Cover Needle Bearing Installer For equivalent regional tools, refer toSpecial Tools. Note:Use this procedure if replacing only...
Stator Shaft Replacement Automatic Transmission Unit      Special Tools J-43765Stator Shaft Installer/Remover Removal Procedure Note:Remove the needle bearing only if replacing both the bearingand the stator shaft. Position the oil pump cover assembly-(2) on apress bed so that...
Steel 4-5-6 Clutch Plate Inspection Automatic      Important: Measure as described below at a minimum of 3locations.Replace any 4–5–6 clutch steel plate thatdoes not meet specifications.Measure the thickness of each 4–5–6clutch steel plate-(1) at dimension A. Specification...
Sun Gear and Sun Gear Shaft Installation Automatic      Sun Gear and Sun Gear Shaft Installation Callout Component Name 1 Sun Gear Shaft Assembly-–-3rd Position Note: You might have to rotate the shaft to align the splines.The sun gear shaft may be pressed into the...
Sun Gear and Sun Gear Shaft Removal Automatic      Sun Gear and Sun Gear Shaft Removal Callout Component Name 1 Sun Gear-–-3rd Position Note:This sun gear has no bushing inside and can only go with the sun gear shaft assembly. 2 Sun Gear Shaft...
Sun Gear Carrier and Sun Gear Installation Automatic      Sun Gear Carrier and Sun Gear Installation Callout Component Name 1 Sun Gear Assembly-–-1stPosition 2 Sun Gear CarrierAssembly-–-1st Position 3 Sun Gear Carrier ThrustBearing-–-1st Position
Sun Gear Shaft Installation Automatic      Sun Gear Shaft Installation Callout Component Name 1 Internal Gear-–-2nd Position 2 Sun Gear Shaft Assembly-–-1st Position 3 Sun Gear Shaft Retaining Ring Note:Do not reuse the retaining ring....
Sun Gear Shaft Sun Gear Carrier 1-3 Clutch Housing and Main Shaft Removal Automatic      Sun Gear Shaft, Sun Gear Carrier, 1-3 Clutch Housing, and Main Shaft Removal Callout Component Name 1 Sun Gear Shaft Assembly-–-1stPosition 2 Internal Gear Thrust BearingAssembly-–-2nd Position 3...
Third Range Automatic - part 2      The 3rd, 5th, andreverse clutch remains applied. With only one clutch applied, thetransmission goes to Neutral-(N). If electrical power is interrupted while the transmission isin third range and the manual selector valve is...
Third Range Automatic      Before making the shift from second to third range, thetransmission control module-(TCM) makes certain all ofthe shift valves are in the correct position with shiftvalve-1, shift valve-2, and shiftvalve-3 de-stroked. Pressure...
Torque Converter Assembly Installation Automatic Torque Converter      Special ToolsJ 46409 Torque Converter Lifting HandlesJ 21366 Torque Converter Retaining Strap For equivalent regional tools, refer toSpecial Tools. Warning:The torque converter dry weight is approximately29- kg-(63-lb). To...
Torque Converter Assembly Removal Automatic Torque Converter      Warning:The torque converter weighs approximately 65 lbs. Personalinjury may result if you lift the torque converterimproperly. Remove the torque converter.
Torque Converter Assembly Removal Automatic Torque Converter      Special Tools J 46409Torque Converter Lifting Handles For equivalent regional tools, refer toSpecial Tools. Removal Procedure Warning:The torque converter dry weight is approximately29- kg-(63-lb). To help avoidpersonal...
Torque Converter Clutch Pulse Width Modulation Solenoid Torque Converter Clutch Solenoid and Wiring Harness Automatic Torque Converter Torque Converter Clutch and Lockup      Special Tools J 28458Seal Protector Retainer Installer Removal ProcedureRaise and support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the transmission oil pan and the filter. Refer toAutomatic Transmission...
Torque Converter Clutch Valve and Spring Replacement Automatic Torque Converter Torque Converter Clutch and Lockup      Removal ProcedureRemove the transmission filter. Refer toAutomatic Transmission Fluid and Filter Replacement. Disconnect the torque converter clutch (TCC) pulse widthmodulation (PWM) solenoid electrical connector.Remove the...
Torque Converter Cover Replacement Automatic Torque Converter      Torque Converter Cover Replacement Callout Component Name Preliminary Procedures Raise the vehicle. Refer toLifting and Jacking the Vehicle. 1 Torque Converter Cover Bolt Caution:Refer toFastener Caution....
Torque Converter End Play Inspection Automatic Torque Converter      Tools RequiredJ 43764 Torque Converter End Play GaugeJ 5959 Dial Indicator Clamp and AdjusterJ 7872 Magnetic Base Dial Indicator Position the torque converter-(3) on the work table so that the pump hub is facingup.Install J...
Torque Converter End Play Inspection Automatic Torque Converter      Special ToolsJ-8001Dial Indicator SetJ-26900-13Magnetic Indicator BaseJ-35138Converter End Play CheckerJ-39195Converter End Play Check Tool Inspect the torque converter and replace if any of thefollowing conditions...
Torque Converter Fluid Seal Replacement Automatic Torque Converter      Torque Converter Fluid Seal Replacement Callout Component Name 1 Torque Converter Fluid Seal Retaining Ring 2 Torque Converter Fluid Seal Assembly Note:The seal can be installed by hand. Special Tool...
Torque Converter Fluid Seal Replacement Automatic Torque Converter      Tools RequiredJ 24171-A Seal and Dust Shield RemoverJ 43772 Torque Converter Seal InstallerRemoval Procedure Remove the torque converter from the transmission. Refer toTorque Converter Replacement.Obtain J 24171-A seal and...
Torque Converter Housing Bolt Seal Replacement Automatic Torque Converter      Removal Procedure Remove the torque converter from the transmission. Refer toTorque Converter Replacement.Remove any of the 10 bolts-(1), bolt heads shaded,where leakage at the bolt head is suspected. Note:The bolts-(1)...
Torque Converter Housing Cleaning and Inspection Automatic Torque Converter      Torque Converter Housing Cleaning and Inspection Callout Component Name Preliminary ProceduresThoroughly clean the torque converter housing assembly, including threads, with cleansolvent.Clean sealing surfaces.Inspect...
Torque Converter Housing - Fluid Pump Cover Side Automatic      Torque Converter Housing– Fluid Pump CoverSide (2) Line (4) Converter Feed (5) Converter Feed Limit (6) TCC Release (7) TCC Apply (8) Cooler Feed (9) Center Lube (10) Regulator Apply (38)...
Torque Converter Housing from Pump Assembly Disassemble Automatic Torque Converter      Position the converter housing/oil pump covermodule-(2) on the work table so that the torqueconverter housing is facing up.Remove the oil seal assembly-(1). Remove 10-bolts-(1). Remove the seals-(2) from thebolts-(1)....
Torque Converter Housing Installation Automatic Torque Converter      Special ToolsDT-49037MorTorq BitJ-41510T-50 Plus Bit For equivalent regional tools, refer toSpecial Tools. Note: Ensure the converter housing and case face are clean beforeinstalling a new pump seal.When installing a new...
Torque Converter Housing with Fluid Pump Disassemble Automatic Torque Converter      Torque Converter Housing with Fluid Pump Disassemble Callout Component Name Caution:Do not loosen or remove the 6 bolts securing the clutchsupport to the pump cover assembly. These bolts have been installedand...
Torque Converter Housing with Fluid Pump Installation Automatic Torque Converter      Torque Converter Housing with Fluid Pump Installation Callout Component Name 1 NEW Fluid Pump Seal 2 Torque Converter-(with Fluid Pump) HousingAssembly Caution:Ensure the turbine shaft-(O-ring) seal is...
Torque Converter Housing with Fluid Pump Assemble Automatic Torque Converter      Torque Converter Housing with Fluid Pump Assemble Callout Component Name 1 Fluid Pump Slide Fluid Seal Ring 2 Fluid Pump Slide-(O-Ring) Seal 3 Fluid Pump Slide Pivot Pin 4 Fluid Pump Slide...
Torque Converter Housing with Fluid Pump Assembly Installation Automatic Torque Converter      Special ToolsJ 36850 Transjel® LubricantJ-45023 Control Main Filter Wrench For equivalent regional tools, refer toSpecial Tools. Warning:The torque converter housing/oil pump cover assembly dryweights are approximately...
Torque Converter Housing with Fluid Pump Assembly Removal Automatic Torque Converter      Caution:Refer toTorque Converter Housing/Low and Reverse Clutch Housing Bolt Size Caution. Remove 16-bolts-(1), one bolt-(2), and one bolt-(3). Note:NEW copper washers are required under the bolt heads-(4) when servicing...
Torque Converter Housing with Fluid Pump Removal Automatic Torque Converter      Torque Converter Housing with Fluid Pump Removal Callout Component Name Caution:The valve body assembly must be removed prior to removing thetorque converter (with fluid pump) housing assembly. Failure toensure this...
Torque Converter Inspection Automatic Torque Converter      Important:Replace the torque converter if it does not meetspecifications. Measure the OD of torque converter hub-(1) atdimension A, the bushing wear area. Torque Converter Hub OD Dimension A must equal or exceed...
Torque Converter Installation and Holding Fixture Removal Automatic Torque Converter      Torque Converter Installation and Holding Fixture Removal Callout Procedure Preliminary Procedure Rotate the transmission so that the fluid pan assembly is down. 1 Transmission Case Assembly Special ToolsDT...
Torque Converter Installation Automatic Torque Converter      Special Tools J-21366Converter Holding Strap Warning:The torque converter weighs approximately 65 lbs. Personalinjury may result if you lift the torque converterimproperly. Caution:Make sure that the torque converter...
Torque Converter Leak Test Automatic Torque Converter      Special ToolsJ 43763Torque Converter Leak Test PlugJ 21369-FTorque Converter Leak Test Fixture For equivalent regional tools, refer toSpecial Tools. .. Note:The torque converter leak test requires a large container ofwater...
Torque Converter Removal and Holding Fixture Installation Automatic Torque Converter      Torque Converter Removal and Holding Fixture Installation Callout Component Name 1 Torque Converter Assembly 2 Transmission Case Assembly Note: Rotate the transmission so that the converter housing is up...
Torque Converter Replacement Automatic Torque Converter      Special ToolsJ 21366 Converter Holding StrapJ 46409 Torque Converter Lifting HandlesJ 44723 Transmission/Stand Adaptor PlateRemoval Procedure Remove the transmission from the vehicle. Refer toTransmission...
Torque Dampener Housing and Fluid Pump Cover Disassemble Automatic Transmission Unit Transmission Oil Pump      Torque Dampener Housing and Fluid Pump Cover Disassemble Callout Component Name 1 A/Trans Fluid Pump CoverBolt-M6-x-1.0-x-45(Qty:-18) 2 A/Trans Fluid Pump Cover Assembly 3 A/Trans Fluid Pump Slide...
Torque Dampener Housing and Fluid Pump Cover Assemble Automatic Transmission Unit Transmission Oil Pump      Torque Dampener Housing and Fluid Pump Cover Assemble Callout Component Name Preliminary Procedure If installing a NEW pump rotor and slide into the torque dampener housing or a NEWtorque dampener housing, ensure to...
Torque Dampener Housing and Fluid Pump Cover Installation Automatic Transmission Unit Transmission Oil Pump      Torque Dampener Housing and Fluid Pump Cover Installation Callout Component Name 1 A/Trans Torque Dampener Housing Gasket Note:Do not reuse the gasket. Replace with a NEW gasket. 2 A/Trans Torque Dampener...
Torque Dampener Housing Assembly Automatic      Torque Dampener Housing Assembly (2) Line (4) Decrease (7) Cooler Feed (8) Lube (9) Regulator Lube (12) PCS Line (13) Auxiliary Suction (14) Auxiliary Line (38) Exhaust (39) Seal...
Torque Dampener Housing Cleaning and Inspection Automatic      Torque Dampener Housing Cleaning and Inspection Callout Component Name Preliminary ProceduresThoroughly clean the torque dampener housing assembly, including threads, with cleansolvent.Clean sealing surfaces.Inspect...
Torque Dampener Housing Removal Automatic      Torque Dampener Housing Removal Callout Component Name Caution:The valve body assembly must be removed prior to removing thetorque dampener (with fluid pump) housing assembly. Failure toensure this will cause severe...
Transmission Assemble Automatic Transmission Unit      Clean the gasket surface and apply sealant. Install the casing. Caution:Refer toFastener Caution. Using a 10-mm wrench, install the 14-screws that secure the casing.Tighten the screws to 31-Y (23-lb-ft.). Install...
Transmission Assemble Automatic Transmission Unit      Using a drive tool, install a new bearing, ifequipped. Using locking pliers, install the bearing snap ring, ifequipped. Using a drive tool, if required, install a new extension oilseal. Using a driving tool,...
Transmission Case and Related Components Manual      Transmission Case and Related Components (1) Shift Housing VentBreather (2) Modulator Cable AnchorBracket (3) Transmission Brace BracketBolt (4) Transmission Lubricant Fill PlugCap (4) Transmission...
Transmission Case and Related Components Manual      Transmission Case and Related Components (1) Clutch Housing (2) Yoke (3) Main Shaft Washer (4) Nut (5) Coupling Flange (6) Main Shaft Cover Oil Seal (7) Rear Cover Bolts (8) Rear Hub Screw...
Transmission Case Cleaning and Inspection Automatic      Transmission Case Cleaning and Inspection Callout Component Name Caution:After cleaning the transmission components, allow to air dry.Do not use cloth or paper towels in order to dry any transmissioncomponents. Lint...
Transmission Converter Cover Replacement Automatic Transmission Unit      Transmission Converter Cover Replacement Callout Component Name Preliminary Procedure Raise the vehicle. Refer toLifting and Jacking the Vehicle. 1 Torque Converter Cover Bolt Caution:Refer toFastener...
Transmission Disassemble Automatic Transmission Unit      Remove the vehicle speed sensor-(VSS)screw. Remove the VSS. Remove the main shaft nut. Remove the main shaft nut from the main shaft. Remove the rear cover bolts.Remove the rear cover. Remove the bolts from...
Transmission Disassemble Automatic Transmission Unit      Place the transmission on a workbench. Using a 10-mm socket, remove the shift controlhousing bolt. Remove the shift control cover. Remove the park/neutral position and backup lampswitch. Using a 10-mm socket,...
Transmission End Play Check Automatic Transmission Unit      Special ToolsJ-8001 Dial Indicator SetJ-24773-A Oil Pump RemoverJ 25022 End Play Fixture AdapterJ-25025-7A Dial Indicator PostJ-34725 End Play Checking AdapterJ-43205 End Play Fixture Adapter (300-mm) Note:Torque converter...
Transmission End Play Check Automatic Transmission Unit      Special ToolsJ-8001 Dial Indicator SetJ-24773-A Oil Pump RemoverJ-25022 End Play Fixture Adapter (245-mm and 258-mm)J-25025-7A Dial Indicator Mounting PostJ-34725 End Play Checking Adapter (298-mm)J-43205 End Play Fixture...
Transmission End Play Measurement Automatic Transmission Unit      Special ToolsJ 5959 Dial Indicator SetJ 24446 Rear Bearing Installer Using J 24446 rear bearing installer-(1), install the ball bearing-(2) until the bearing seats. Align the retaining ring-(1) so that the beveled edge...
Transmission Fluid Auxiliary Cooler Inlet Pipe Replacement Automatic      Removal ProcedureRemove the front bumper impact bar. Refer toFront Bumper Impact Bar Removal and Installation. -. :7 Remove the transmission fluid cooler hose/pipe-(1) from the auxiliary oil cooler.Refer toTransmission...
Transmission Fluid Auxiliary Cooler Outlet Pipe Replacement Automatic      Removal ProcedureRemove the radiator grille. Refer toFront Grille Replacement. Remove the transmission fluid auxiliary cooler outlet pipefrom the auxiliary oil cooler-(1). Refer toTransmission Fluid Cooler Hose/Pipe...
Transmission Fluid Auxiliary Cooler Replacement (Diesel) Automatic      Transmission Fluid Auxiliary Cooler Replacement Callout Component Name Preliminary ProceduresRemove the radiator grille. Refer toFront Grille Replacement.Place a drain pan under the vehicle.Disconnect the transmission...
Transmission Fluid Auxiliary Cooler Replacement Automatic      Removal Procedure Remove the front grill assembly. Refer toFront Grille Replacement.Place a drain pan under the vehicle.Disconnect the transmission oil cooler lines from theauxiliary cooler. Refer toTransmission Fluid...
Transmission Fluid Auxiliary Cooler Replacement (Gas) Automatic      Removal Procedure Remove the radiator grille. Refer toFront Grille Replacement.Place a drain pan under the vehicle.Disconnect the transmission oil cooler lines from theauxiliary cooler. Refer toTransmission Fluid Cooler...
Transmission Fluid Cooler Flushing and Flow Test Automatic Transmission Oil Cooler - part 3      Perform Flow Test.Perform Code Recording Procedure.Code Recording Procedure important: to operate machine, supply atf must be greater than 65 f. flow1.0 75f cycle a1 odfb2 important: 32 quart maximum capacity supply vessel....
Transmission Fluid Cooler Flushing and Flow Test Automatic Transmission Oil Cooler - part 2      Record the minimum flow rate in GPMsand the supply fluid temperature for further reference. Example Fluid temperature: 75°FCooler type: Steel The MINIMUM flow rate for this example would be0.8-GPM. Inspect transmission oil...
Transmission Fluid Cooler Flushing and Flow Test Automatic Transmission Oil Cooler      GM studies indicate that plugged or restricted transmissionoil coolers and pipes cause insufficient transmission lubricationand elevated operating temperatures which can lead to prematuretransmission failure. Many repeat...
Transmission Fluid Cooler Hose Pipe Quick-Connect Fitting Disconnection and Connection Automatic ATF Lines      Removal Procedure Important:Perform the following procedure when removing the retainingrings and cooler lines from the quick connect fittings located onthe radiator and/or the transmission. Pull the plastic cap back from...
Transmission Fluid Cooler Hose Pipe Quick-Connect Fitting Disconnection and Connection Automatic ATF Lines      Special ToolsDT-28585Universal Snap Ring Remover for the 5/8 inchLineDT-41623-B3/8 inch Line Quick Release ToolRemoval ProcedureRemove the plastic caps from the quick connect fittings bypulling the caps back along the pipe...
Transmission Fluid Cooler Hose Pipe Replacement Automatic ATF Lines      Removal ProcedureRemove the front bumper impact bar. Refer toFront Bumper Impact Bar Replacement.Remove the radiator grille. Refer toFront Grille Replacement. Remove the transmission fluid cooler hose from the auxiliary oil...
Transmission Fluid Cooler Hose Pipe Replacement Automatic ATF Lines      Removal ProcedureRemove the front bumper impact bar. Refer toFront Bumper Impact Bar Removal and Installation. Remove the transmission fluid cooler hose-(1) fromthe auxiliary oil cooler. Refer toTransmission Fluid Cooler...
Transmission Fluid Cooler Pipe Fitting Seal Replacement Automatic Transmission Oil Cooler      Transmission Fluid Cooler Pipe Fitting Seal Replacement Callout Component Name 1 Trans Fluid Cooler Pipe Fitting Seal (Qty:-2) Special ToolsDT 47770 Seal InstallerJ 45201 Cooler Line Seal Remover
Transmission Fluid Cooler Pipe Replacement Automatic Transmission Oil Cooler      Transmission Fluid Cooler Pipe Replacement Callout Component Name Preliminary ProceduresRemove the front bumper impact bar. Refer toFront Bumper Impact Bar Replacement.Raise and support the vehicle. Refer toLifting...
Transmission Fluid Cooler Pipe Seal Replacement Automatic Transmission Oil Cooler      Transmission Fluid Cooler Pipe Seal Replacement Callout Component Name 1 Trans Fluid Cooler Pipe Fitting Seals(Qty:-2) Special ToolsDT-47770Seal InstallerDT-45201Cooler Line Seal Remover For equivalent regional...
Transmission Fluid Cooler Pipe Seal Replacement Automatic Transmission Oil Cooler      Special ToolsDT-45201 Cooler Line Seal RemoverDT-47770 Seal Installer For equivalent regional tools, refer toSpecial Tools. Removal ProcedureRaise and support the vehicle. Refer toLifting and Jacking the Vehicle.Remove the...
Transmission Fluid Drain and Fill Automatic      Removal ProcedureRaise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Place a suitable drain pan under the transmission in order tocatch the drained transmission fluid. Remove the oil fill...
Transmission Fluid Drain and Fill Automatic      Special Tools J 36511 Oil Fill/Drain Plug Hex Bit (17-mm) Removal Procedure Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Using J 36511 oil fill/drain plug hex bit (17-mm) remove the oil...
Transmission Fluid Filler Tube and Seal Replacement Automatic Transmission Unit      Transmission Fluid Filler Tube and Seal Replacement Callout Component Name Preliminary Procedure Remove the transmission. Refer toTransmission Replacement. 1 Transmission Fluid Filler Tube Nut Caution:Refer...
Transmission Fluid Filler Tube and Seal Replacement Automatic Transmission Unit      Removal Procedure Unlock the transmission oil level indicator.Remove the transmission oil level indicator. Note:Tie the engine wiring harness, between the oil level indicator tube and engine, tothe engine, so when...
Transmission Fluid Filler Tube and Seal Replacement Automatic Transmission Unit      Removal Procedure The transmission case has provisions that enable the filltube to be installed on either the right or left side of thetransmission. Proceed to step-9 if servicing the plugand/or seal opposite the fill...
Transmission Fluid Filler Tube and Seal Replacement Automatic Transmission Unit      Removal Procedure Unlock the transmission oil level indicator.Remove the transmission oil level indicator.Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Support the transmission using a...
Transmission Fluid Filler Tube Plug and Transmission Case Locating Pin Replacement Automatic Transmission Unit      Special Tools J 43780Transmission Case Locating Pin Installer For equivalent regional tools, refer toSpecial Tools. Transmission Case Fill Plug Replacement Remove the fill tube plug-(1).Remove the fill tube...
Transmission Fluid Filter Adapter Replacement Automatic ATF Filter      Removal Procedure Note: DO NOT drain the fluid if only the transmission external oilfilter adapter is being replaced.Use a standard strap-type filter wrench to remove or installthe transmission external oil filter.Remove...
Transmission Fluid Inspection Automatic      Remove the transmission fluid from torqueconverter-(1).Examine the transmission fluid for the following.Evidence of foreign matterMetal particlesOther contaminatesIf the torque converter is damaged, replace the...
Transmission Fluid Pan and Filter Assembly Installation Automatic Transmission Unit ATF Pan      Install the transmission internal oil filterseal-(6) onto the transmission internal oilfilter-(5).Align the neck of the transmission internal oilfilter-(5) with the filter hole in the transmissioncase.Install the...
Transmission Fluid Pan and Filter Assembly Removal Automatic Transmission Unit ATF Pan      Remove the transmission oil panscrews-(76).Remove the transmission oil pan-(75) and thetransmission oil pan gasket-(73). Remove the transmission oil filterassembly-(72).The filter may help in diagnosis. Cut away the top...
Transmission Fluid Pan and Filter Assembly Removal Automatic Transmission Unit ATF Pan      Special Tools J 44587Main Shaft Holder For equivalent regional tools, refer toSpecial Tools. Caution:Do not rotate the transmission from the nose-up positionwithout installing J-44587. Failure to installJ-44587 and...
Transmission Fluid Pan Fluid Filter and Auxiliary Fluid Pump Filter Installation Automatic Transmission Unit Transmission Oil Pump      Transmission Fluid Pan, Fluid Filter, and Auxiliary Fluid Pump Filter Installation Callout Component Name 1 A/Trans Fluid Filter Seal Assembly Note:Install a NEW seal assembly. Special ToolsDT 47848 Water Pump...
Transmission Fluid Pan Fluid Filter and Auxiliary Fluid Pump Filter Removal Automatic Transmission Unit Transmission Oil Pump      Transmission Fluid Pan, Fluid Filter, and Auxiliary Fluid Pump Filter Removal Callout Component Name 1 A/Trans Fluid Pan Bolt-M8-x-1.25-x-20-–-External (Qty:-13) 2 A/Trans Fluid Pan Assembly 3...
Transmission Fluid Pan Installation Automatic Transmission Unit ATF Pan      Place the transmission oil pan gasket-(73) on thecase.Place the transmission oil pan-(75) on thecase. Caution:Refer toFastener Caution. Install all of the transmission oil pan screws (76). Tightenthe screws to16-Y(11.8-lb-ft).
Transmission Fluid Pan Installation Automatic Transmission Unit ATF Pan      Transmission Fluid Pan Installation Callout Component Name 1 Fluid Pan Gasket Note:The fluid pan gasket is reusable. Inspect the gasket to determine if it may be reused.If the gasket is stuck to the case or pan,...
Transmission Fluid Pan Replacement Automatic Transmission Unit ATF Pan      Transmission Fluid Pan Replacement Callout Component Name Caution:Use Dexron-VI transmission fluid only. Failure touse the proper fluid may result in transmission internaldamage. Preliminary ProceduresRaise and...
Transmission Fluid Pressure Test Hole Plug External Filter and Fluid Cooler Pipe Retainer Removal Automatic Transmission Oil Cooler      Special Tools J 45023 Control Main Filter Wrench Remove the transmission line pressure test hole plug-(5).Remove the O-ring-(4) from the pressure test hole plug-(5).Using J 45023 control main filter wrench -(9) or a...
Transmission Fluid Pump Cover Assemble Automatic - part 2      Position the oil pump cover assembly-(5) on thework table so that the stator shaft-(4) is facingup.Align, as a unit, the oil pump assembly-(1) andthe torque converter housing to case channel plate-(3)so that the following...
Transmission Fluid Pump Cover Assemble Automatic      Special ToolsJ-24459-5Spring Compressor AdapterJ 36850Transjel® LubricantJ-43770Main Lube Converter Relief Valve SpringCompressorJ 43772Torque Converter Seal InstallerJ-43773Valve Spring Compressor For equivalent regional...
Transmission Fluid Pump Cover Disassemble Automatic      Special ToolsJ-24459-5Spring Compressor AdapterJ-43770Main Lube, Converter Relief Valve SpringCompressorJ-43773Valve Spring Compressor For equivalent regional tools, refer toSpecial Tools. InstallJ-24459-5adapter-(1)...
Transmission Fluid Pump Seal Replacement Automatic      Transmission Fluid Pump Seal Replacement Callout Component Name 1 A/Trans Torque Dampener Fluid Seal Retaining Ring 2 A/Trans Fluid Pump Seal Special Tools J 45000 Seal Remover
Transmission Front Case Assemble Manual      Caution:Refer toFastener Caution. Using a 13-mm socket, install the 2-oil baffle screws . The anchor support assembly shows, 3-springs, 3-bushings, 2-pistons, and 1-support. Assemble the 3-springs and 3-bushings....
Transmission Front Case Disassemble Manual      Using a 13-mm wrench, remove the7-screws from the bearing retainer. Using a screwdriver, remove the gear train cup. Remove the gear train adjustment shims. Remove the gear train spacer. Using a punch and a...
Transmission Identification Information Automatic Transmission Unit      (1) Model Year (2) Model Code (3) Transmission Family (4) Transmission AssemblyNumber (5) Julian date (6) Sequential Serial Number (7) Source Code (8) Broadcast Code (9) Bar Code (10)...
Transmission Identification Information Automatic Transmission Unit      24224205 6cya 616cyah0cb1 10 87 24250602 21 oooooooooox y1 /\\\ 713115 (1) Model Year (2) Model Code (3) Transmission Family (4) Transmission AssemblyNumber (5) Julian date (6) Sequential Serial...
Transmission Identification Information - Ramos Build Automatic      Ramos Arizpe, Mexico Build (1) 9 = 2009 (2) Model (3) Hydra-Matic4L60-E (4) Plant of Manufacture, 4 isRamos (5) Julian Date or Day of theYear (6) Shift Built, See Shift BuildChart (7) Transmission...
Transmission Identification Information - Toledo Build Automatic      Toledo Build 9cad187a 16588320 ca 137 16588320 (1) 9 = 2009 (2) Model (3) Hydra-Matic4L60-E (4) Julian Date or Day of theYear (5) Shift Built, See Shift BuildChart (6) Serial Number (7) Case/Pan...
Transmission Mount Replacement (4WD) Transmission Mounts      Transmission Mount Replacement Callout Component Name Preliminary ProceduresRaise and support the vehicle. Refer toLifting and Jacking the Vehicle.Support the transmission with a transmission jack. 1...
Transmission Mount Replacement Transmission Mounts      Removal Procedure Raise and support the vehicle. Refer toLifting and Jacking the Vehicle.Support the transmission with a transmission jack.Remove the transmission mount to the transmission supportretaining nut or nuts....
Transmission Output Shaft Seal Replacement (Four Wheel Drive) Automatic Transmission Unit      Transmission Output Shaft Seal Replacement Callout Component Name Preliminary Procedure Remove the transfer adapter from the transmission. Refer to the appropriate procedure: Transfer Case Adapter Replacementfor the...
Transmission Parts Kit Specifications Automatic Transmission Unit - part 3      etaining Ring Package Note:Callouts with boxes around them indicate part is included in the service kit. Calloutswithout boxes are shown for relationship purposes only. Retaining Ring Package Callout Quantity Component...
Transmission Parts Kit Specifications Automatic Transmission Unit - part 2      lutch Plate Package Note:Callouts with boxes around them indicate part is included in the service kit. Calloutswithout boxes are shown for relationship purposes only. Clutch Plate Package Callout Quantity Component Name...
Transmission Parts Kit Specifications Automatic Transmission Unit      Table 1: A/Trans Fluid Filter Kit Table 2: A/Trans Fluid Pump Rotor Package Table 3: A/Trans Service Seal Kit Table 4: Clutch Plate Package Table 5: A/Trans Electrical Connector Passage Sleeve Seal Kit...
Transmission Rear Case Assemble Manual      The reverse assembly arrangement and support shows 2-roller cages, a spacer, and thereverse gear and screw. Place the roller cages and spacer inside the gear. Install the assembly inside the case. Caution:Refer...
Transmission Rear Case Disassemble Manual      Using a GMM Allen wrench, remove the reverse gear supportscrew. Remove the reverse shaft support. Remove the reverse gear, 2-roller cages, andspacer.
Transmission Rear Mount Replacement Manual      Removal Procedure Caution:Broken or deteriorated mounts can cause misalignment anddestruction of certain drive train components. When a single mountbreaks, the remaining mounts are subjected to abnormally highstresses....
Transmission Replacement Automatic Transmission Unit - part 3      Connect the electrical connectors on the transmission and transfer case, if equipped. Install the fuel line bracket and nut to the transmission converter housing stud.Tighten the nut to 18-Y (13-lb-ft). Install the fuel...
Transmission Replacement Automatic Transmission Unit - part 2      Refer toTransmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection.Plug the transmission oil cooler line fittings in the transmission case, if necessary.If the vehicle is equipped with a power take...
Transmission Replacement Automatic Transmission Unit      Special ToolsJ 21366 Converter Holding StrapJ 44257 Connector Removal Tool For equivalent regional tools, refer toSpecial Tools. Removal Procedure Note:If replacing a failed transmission, the “Fast Learn” (adapt) procedure...
Transmission Replacement Automatic Transmission Unit - part 3      Refer toTransmission Fluid Cooler Pipe Replacement.Install the transfer case, if equipped. Refer toTransfer Case Assembly Replacement. Perform the following 2-steps if equipped with 2WD:Install the fuel pipe...
Transmission Replacement Automatic Transmission Unit - part 2      Remove the transmission electrical harness retaining bolt-(1).Disconnect the transmission electrical harness connector-(7) from the vehicle speedsensor-(5).Disconnect the transmission electrical harness connector-(4) from the...
Transmission Replacement Automatic Transmission Unit      Special Tools J 21366 Converter Holding Strap Removal Procedure Danger:Always perform the High Voltage Disabling procedure prior toservicing any High Voltage component or connection. PersonalProtection Equipment (PPE) and...
Transmission Replacement Automatic Transmission Unit - part 2      Caution:Refer toFastener Caution. Install the 8-bolts securing the transmission to the engine and tighten to 50-Y (37-lb-ft). Connect the transmission vent hose.Install the wire harness to the transmission.Connect the...
Transmission Replacement Automatic Transmission Unit      Special Tools J 21366 Converter Holding Strap Removal ProcedureDisconnect the negative battery cable. Refer toBattery Negative Cable Disconnection and Connection.Raise and suitably support the vehicle. Refer toLifting and...
Transmission Replacement Automatic Transmission Unit - part 2      Caution:Refer toFastener Caution. Install the 5-studs and one bolt securing the transmission to the engine and tightento 47-Y (35-lb-ft). Install the stud-(2) and bolt-(1) securing the transmission to the engine and...
Transmission Replacement Automatic Transmission Unit      Special Tools J 21366 Converter Holding Strap For equivalent regional tools, refer toSpecial Tools. Removal ProcedureDisconnect the negative battery cable. Refer toBattery Negative Cable Disconnection and Connection.Raise...
Transmission Replacement Manual      Special Tools J-42371 Hydraulic Clutch Line Separator Removal ProcedureRemove the shift lever. Refer toTransmission Control Lever Knob Replacement.Remove the propeller shaft. Refer toOne-Piece Propeller Shaft...
Transmission Replacement Manual      Special Tools J 42371 Hydraulic Clutch Line Separator Removal Procedure Shift the transmission into 3rd or 4th gear.Remove the shift lever assembly. Refer toTransmission Control Replacement.Remove the propeller shaft....
Transmission Vent Installation Automatic Transmission Unit      Install the vent-(1, 2).Gently tap the vent until seated.
Transmission Vent Removal Automatic Transmission Unit      Gently pry the vent-(2) from the transmission case.If the vent cap-(1) comes off, gently pry the stem from the transmission case.
Turbine Shaft Bushing Inspection Automatic Transmission Unit Input Shaft      Important:Replace the turbine shaft bushing if specifications are notmet. Inspect the bushing-(2) inside the end of theturbine shaft-(1) for damage.Measure the inside diameter of the turbine shaft bushing atdimension A....
Turbine Shaft Seal Installation Automatic Transmission Unit Input Shaft      Install the O-ring (618) on the turbine shaft. O-ringlocation is location dependent.
Turbine Shaft Seal Removal Automatic Transmission Unit Input Shaft      Remove the O-ring (618) from the turbine shaft. O-ringlocation is model dependent.
Vehicle Speed Sensor and Case Extension Installation Automatic      Special ToolsJ-21426Rear Seal InstallerJ-39440Extension Housing Seal Installer Using theJ-21426seal installer, install an output shaft sleeve-(690) and anoutput shaft seal-(691). Do not push the sleeve past the machined...
Vehicle Speed Sensor and Case Extension Removal Automatic      Special Tools J-29837-AOutput Shaft Support Fixture Remove the sensor retaining bolt-(35).Remove the speed sensor-(36) and O-ringseal-(37). Remove the case extension bolts-(32).Remove the case extension-(31) and the...
Vehicle Speed Sensor Replacement Automatic      Removal Procedure Raise and suitably support the vehicle. Refer toLifting and Jacking the Vehicle.Disconnect the vehicle speed sensor (VSS) electricalconnector (2). Remove the VSS bolt (2).Remove the VSS (1).Remove the...
Vehicle Speed Sensor Replacement Manual      Vehicle Speed Sensor Replacement Callout Component Name Preliminary Procedure Raise and support the vehicle. Refer toLifting and Jacking the Vehicle. 1 Vehicle Speed Sensor Bolt Caution:Refer toFastener...
Vent Hose Replacement (2WD) Automatic      Vent Hose Replacement Callout Component Name Preliminary Procedure Raise the vehicle. Refer toLifting and Jacking the Vehicle. 1 Transmission Vent Hose ProcedureDisconnect hose retainers from transmission...
Wiring Harness Installation Automatic      Special Tools J-44247Internal Wiring Harness Installer For equivalent regional tools, refer toSpecial Tools. Install the internal wiring harness connector by hand intothe transmission case.UsingJ-44247installer-(2),...
Wiring Harness Removal Automatic      Using a 30–32-mm(1-3/16-in) deep well socket or box endwrench, depress the 4 tabs on internal wiring harnessconnector-(1). With the tabs depressed, gently pop theconnector into and through the transmission case with the...
Wiring Harness Replacement Automatic      Special ToolsJ 44247 Internal Wiring Harness InstallerJ 44257 Main Wiring Harness Connector RemoverRemoval Procedure Warning:Refer toBattery Disconnect Warning. Remove the oil pan and transmission internal oil filter. Refer...
Low and Reverse Clutch Spacer Plate Selection Automatic Transmission Unit Automatic Clutches      Low and Reverse Clutch Spacer Plate Selection Measured Dimension Selective Plate Identification Thickness 28.065–27.545-mm(1.105–1.084-in) None 1.684–1.829-mm(0.066–0.072-in)...
1-2 Accumulator Piston Spring Selection Automatic Transmission Unit Trans Accumulator      1-2 Accumulator Piston Spring Selection One Spring Two Springs 1CBD 1KBD 1KPD 1LPD 1SHD 1TSD 1STD 1TTD
Electronic Park Lock Description and Operation Automatic Transmission Unit Parking Lock Mechanism      If the vehicle is equipped with automatic transmission and a floor mounted consolegear shift, it has an electronic park lock system (EPL). The EPL system purpose isto prevent the ignition key from being turned to the OFF...
Fluid Passages Automatic      Figure 1: Torque Converter Housing - Fluid Pump Cover Side Figure 2: Fluid Pump Cover - Torque Converter Housing Side Figure 3: Fluid Pump Cover - Case Side Figure 4: Case - Top Channel Plate Side Figure...
Axial Play Specifications Manual      The axial play should be maintained upon assembling the mainshaft unit, the 5th gear assembly, the gear train, and the reversegear. Axial Play Specifications Application Specification Metric English 1st Gear...
Solenoid and Clutch Chart (PCS1 PCS2 SS1 SS2 and SS3) Automatic      Solenoid and Clutch Chart Range Status Logic State Clutch to Line Pressure Control Solenoids Shift Solenoids PCS1 PCS2 SS1 SS2 SS3 Steady State R Sump Temp below ?25°C Low/Reverse Clutch...
Transmission Component and System Description Automatic Transmission Unit      The mechanical components of the Hybrid Two-Mode2ML70 Transmission are as follows: Torque dampener assemblyVane-type main fluid pump assemblyGerotor type auxiliary fluid pump assemblyInput shaft and internal assemblySun gear...
Fluid Pump Selective Specifications Automatic Transmission Unit Transmission Oil Pump      Fluid Pump Selective Specifications Size Classification Thickness (mm) Thickness (in) Note: Rotor and slide must be chosen from the same sizeclassification as the oil pump body.Allowable rotor and slide to fluid pump...
Transmission General Specifications Automatic Transmission Unit      Transmission General Specifications Name 6L45 6L50 6L80 6L90 RPO Codes MYA MYB MYC MYD Production Location Silao, Mexico; Strasbourg, France; Toledo,OH-(USA) Silao, Mexico; Strasbourg, France;...
Transmission General Information Automatic Transmission Unit      When attempting to diagnose a suspected 1000 Seriestransmission problem, always begin by conducting the FunctionalTest Procedure. Refer toFunctional Test. This procedure indicatesthe proper path for diagnosing the transmission...
Transmission General Description Automatic Transmission Unit      The Hydra-matic 6-Speed RWD is a fully automatic, 6-speed,rear-wheel drive, electronic-controlled transmission. It consistsprimarily of a 4-element torque converter, an integral fluid pumpand converter housing, a single and...
Fluid Capacity Specifications Automatic      Fluid Capacity Specifications Application Specification Metric English Pan Removal and Filter Replacement – ApproximateCapacity-(6L80/6L90) 5.7-liters 6.0-quarts Overhaul – ApproximateCapacity-(6L80/6L90)...
Selective Components Specifications Automatic      Table 1: 1–2–3–4 ClutchBackplate Table 2: Low and Reverse Clutch Piston Housing Selective Shim Table 3: Low and Reverse Clutch Steel Plate Minimum Thickness Table 4: Low and Reverse Clutch Steel Selective...
Pressure Switch Manifold (PSM) Logic Automatic      Pressure Switch Manifold (PSM) Logic Range Pressure Switch 1– N/O Pressure Switch 2– N/O Pressure Switch 3– N/O Pressure Switch 4– N/C Switch Status Scan Tool Status Switch Status Scan Tool Status Switch Status...
Forward Clutch Backing Plate Selection Automatic Transmission Unit Automatic Clutches      Plate Thickness Identification 6.92–7.07-mm(0.272–0.278-in) A 6.33–6.48-mm(0.249–0.255-in) B 5.74–5.89-mm(0.226–0.232-in) C 5.15–5.30-mm(0.203–0.208-in) D 4.56–4.71-mm(0.180–0.185-in)...
Reverse Input Clutch Backing Plate Selection Automatic Transmission Unit Automatic Clutches      Reverse Input Clutch Backing Plate Selection Table Plate Thickness Identification 7.249–7.409-mm(0.285–0.292-in) 2 6.678–6.519-mm(0.263–0.257-in) 3 5.947–5.787-mm(0.234–0.228-in) 4 Backing Plate...
Transmission General Information Automatic Transmission Unit      How to Use This Section This section provides the following information: General diagnosis information on transmissionsProcedures for diagnosing the Hydra-matic transmission When you diagnose any condition of the...
Fastener Tightening Specifications (On Vehicle) Automatic      Fastener Tightening Specifications Application Specification Metric English Flywheel Inspection Cover Stud 12-Y 106-lb-in Transmission Mount Transmission – Side Bracket Bolts-(Qty:-5) First Pass...
Fastener Tightening Specifications - 4WD Driveline Control Automatic      Fastener Tightening Specifications Application Specification Metric English Control Valve Assembly to Main Housing Bolts 12-Y 106-lb-in Converter Housing/Oil Pump Cover Assembly to Transmission Case Bolts...
Torque Converter End Play Specifications Automatic Torque Converter      Torque Converter End Play Check Torque Converter Size Specification 258-mm (10.16-in) 0.1–0.5-mm(0.004–0.020-in) 280-mm (11.02-in) 0.1–0.5-mm(0.004–0.020-in) 300-mm (11.81-in)...
Axial Play Specifications Manual      Axial Play Specifications Application Specification Metric English 1st Gear 0.05–0.20-mm 0.002–0.008-in 2nd Gear 0.10–0.35-mm 0.004–0.014-in 3rd Gear 0.10–0.35-mm 0.004–0.014-in 5th...
Solenoid and Clutch Chart (TCC PCS) Automatic      Table 1: Solenoid and Clutch Chart (TCC PCS — Range 1–3) Table 2: Solenoid and Clutch Chart (TCC PCS — Range 4–6) Solenoid and Clutch Chart (TCC PCS — Range 1–3) Engine Mode Range 1st 2nd 3rd % TPS 25...
Definitions and Abbreviations Automatic      Throttle Position DefinitionsHeavy Throttle Approximately 75% of accelerator pedal travel Light Throttle Approximately 25% of accelerator pedal travel Medium Throttle Approximately 50% of accelerator pedal travel Wide-Open...
Line Pressure Automatic      Line Pressure Range Line Pressure @ 600-RPM Line Pressure @ 1500-RPM Neutral Converter 550–730-kPa(80–106-PSI) 570–1,230-kPa(83–178-PSI) Neutral LU 550–800-kPa(80–116-PSI) 600–1,390-kPa(87–202-PSI)...
End Play Specifications Automatic      Transmission End Play Washer Selection Chart Identification Washer Thickness (mm) Washer Thickness (in) 67 1.87–1.97 0.074–0.078 68 2.04–2.14 0.080–0.084 69 2.21–2.31 0.087–0.091 70...
Transmission General Specifications Automatic Transmission Unit      Transmission General Specifications Name 2ML70 RPO Codes M99 Production Location Baltimore, MD (USA) Transmission Drive Rear Wheel Drive 1st Gear Ratio 3.692 Electric or ICE 2nd Gear...
Third and Fourth Clutch Backing Plate Selection Automatic      3rd and 4th Clutch Backing Plate Selection Table Dimension Identification 5.88–5.68-mm(0.231–0.224-in) A 4.99–4.76-mm(0.196–0.187-in) B 4.10–3.90-mm(0.161–0.154-in) C Use a backing plate which...
Fluid Capacity Specifications Automatic      Fluid Capacity Application Specification Metric English Pan Removal 4.7-L 5-qts Overhaul 10.6-L 11-qts 300-mm Torque Converter Approximate Fluid CapacityDry Fill 10.6-L 11.2-qts
Temperature Versus Resistance (Transmission Fluid Temperature Sensor) Automatic      Temperature Versus Resistance Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance °C °F ? ? ? ?45 ?49 128565 141951 155338 ?40 ?40 95826 100735 105644...
Transmission Component and System Description Automatic Transmission Unit      Engine/Transmission Connection The converter housing of 1000 Series transmissions matesdirectly to the engine block. Flexplate drive is used forengine-to-transmission torque transfer. Torque Converter The torque converter is a...
Fastener Tightening Specifications - 4WD Driveline Control      Fastener Tightening Specifications Application Specification Metric English Clutch Actuator Cylinder Bolt 8-Y 71-lb-in Clutch Pedal to Brake Module Bolt 50-Y 37-lb-ft Clutch Pedal to Clutch...
Lubrication Specifications Manual      Lubrication Specifications Application Metric English 1874 MTX Fluid 12550 ET-M81 4.4-L 4.6-qt
Transmission Identification Information Automatic Transmission Unit      Figure 1: Transmission Identification Information - Toledo Build Figure 2: Transmission Identification Information - Ramos Build Figure 3: Bar Code Label Contents Plant and Shift Build Chart Plant Build...
Transmission Internal Mode Switch Logic Automatic Transmission Unit      Internal Mode Switch (IMS) IMS Circuits/Parameter Selector Position Park Reverse Neutral Drive Manual Direction Switch OperatingConditions: Ignition ON, range selector in appropriategear Direction IMS D1...
Transmission Fluid Temperature Sensor Specifications Automatic      Transmission Fluid Temperature Sensor Specifications Temperature Temperature Minimum Resistance Nominal Resistance Maximum Resistance Signal °F °C ? ? ? Volts ?40 ?40 90636 100707 110778 5.00...
Shift Solenoid Valve State and Gear Ratio Automatic Transmission Unit Transmission Shift Solenoids      Shift Solenoid Valve State and Gear Ratio4L60-E/4L70-E Gear 1-2 Shift Solenoid 2-3 Shift Solenoid Gear Ratio 1 ON ON 3.059:1 2 OFF ON 1.625:1 3 OFF OFF 1.000:1 4 ON OFF...
Tow Haul Mode Automatic      Tow/Haul mode significantly changes the transmission shiftpattern to reduce shift cycling and to deliver better performance,control, and cooling when towing or hauling heavy loads. Forinstance: Upshift points are raised at...
Disassembled Views Manual      Figure 1: Transmission Case and Related Components Figure 2: Main Shaft, Input Shaft, and Components Figure 3: Counter Gear Shaft, Reverse Idler, and Components Figure 4: Shift Control and Components
Fluid Capacity Specifications Automatic      Fluid Quantities Transmission Initial Fill Refill Liters Quarts Liters Quarts Allison 1000 12 12.7 7 7.4
Definitions and Abbreviations Automatic - part 2      Tie-Up A condition where two opposing clutch and/or bands areattempting to apply at the same time causing the engine to laborwith a noticeable loss of engine RPM. Noise ConditionsDrive Link Noise A whine or growl that increases...
Definitions and Abbreviations Automatic      Throttle PositionsEngine Braking A condition where the engine friction is used to slow thevehicle by manually downshifting during a zero throttlecoastdown. Full Throttle Detent Downshift A quick apply of the accelerator pedal...
3-5 Reverse Clutch Backing Plate Rivet Damage Caution Automatic Transmission Unit Automatic Clutches      Caution:DO NOT install special tools, J tools, onto the gear thrustplate rivets of the 3rd, 5th, and reverse clutch backing plateassembly. The special tools could damage the gear thrust platerivets.
Transmission Fluid Pressure Switch Logic Automatic      Transmission Fluid Pressure Switch Logic Gear TFP SW-1 *TFP SW-3 TFP SW-4 TFP SW-5 M1 (48-km/h (30-mph)) Low Low Low High M2 (48-km/h (30-mph)) Low Low Low High M3 (48-km/h (30-mph))...
Range Reference Automatic      Range Reference Gear Park Reverse Neutral D P EVT-R N EVT Low 1st 2nd 3rd 4th EVT High Shift Solenoid 1 OFF OFF OFF OFF ON ON ON ON OFF Shift Solenoid 2 OFF OFF OFF...
Transmission Gear Ratio Manual      Transmission Gear Ratio Model 1st 2nd 3rd 4th 5th Reverse TR-3655 4.23 2.34 1.47 1.00 0.81 4.23 TR-4050– GMM 5.81 2.94 1.61 1.00 0.77 5.6 TR-4050 6.16 3.11...
Second Range (With TCC Applied (Tow-Haul)) Automatic      Energizing the torque converter clutch-(TCC)solenoid strokes the TCC valve against the stop, allowing mainpressure to flow to the top of the converter flow valve. Theconverter flow valve is stroked, exhausting converter-in...
Torque Converter Specifications Automatic Torque Converter      Table 1: Torque Converter End Play Specifications Table 2: Torque Converter Wear Limits Specifications Torque Converter End Play Specifications Torque Converter Condition Maximum Allowable End Play New...
Transmission Adaptive Functions (TCM) Automatic Transmission Unit      The 4L60-E transmission utilizes a line pressure controlsystem during upshifts to compensate for the normal wear oftransmission components. By adjusting the line pressure, thetransmission control module (TCM) can maintain...
Transmission General Specifications Automatic Transmission Unit      Transmission General Specifications(4L60-E/4L70-E) Name Hydra-matic 4L60-E/4L70-E RPO Codes M30/M70 Production Location Toledo, Ohio Vehicle Platform (Engine/Transmission) Usage C/K (GMT-900)...
Adhesives Fluids Lubricants and Sealers      Adhesives, Fluids, Lubricants, and Sealers Application Type of Material GM Part Number United States Canada Hydraulic Clutch System Hydraulic Clutch Fluid 12345347 10953517
Range Reference Automatic      Range Reference Table Range Park Reverse Neutral OD D 2 1 Gear - - - 1st 2nd 3rd 4th 1st 2nd 3rd 1st** 2nd 1st 2nd*** 1-2 Shift Solenoid ON* ON* ON* ON OFF OFF ON ON OFF...
Fluid Pump Rotor and Slide Measurement Automatic Transmission Unit Transmission Oil Pump      Oil Pump Rotor and Slide Measurement Thickness (mm) Thickness (in) Oil Pump Rotor 17.948–17.961 0.7066–0.7071 17.961–17.974 0.7071–0.7076 17.974–17.987 0.7076–0.7081 17.987–18.000...
Shift Stabilization Description and Operation Automatic      Shift stabilization is a function within the vehicle'ssoftware/calibration that determines if and when to preventupshifts under load. The purpose of shift stabilization is toreduce shift busyness during conditions that would...
Transmission Internal Mode Switch Logic Automatic Transmission Unit      Transmission Internal Mode Switch Logic Range A B C P P OFF ON ON OFF R Transitional OFF OFF ON OFF R OFF OFF ON ON N ON OFF ON OFF D Transitional...
Transmission Internal Mode Switch Logic Automatic Transmission Unit      Transmission Internal Mode Switch Logic Gear Selector Position Signal A Signal B Signal C Signal P Park LOW HI HI LOW Park/Reverse LOW LOW HI LOW Reverse LOW LOW HI HI...
Transmission General Description Automatic Transmission Unit - part 2      This is done by the drive motor with generator 2ndposition and is electric only. Note: The Autostop feature isenabled in reverse but the engine may start depending on driverrequested axle torque and hybrid battery state of...
Transmission General Description Automatic Transmission Unit      The Hybrid Two-Mode 2ML70 is a fully automatic,variable-speed, rear-wheel drive, electronic-controlledtransmission. It consists primarily of a torque dampener assembly,an integral fluid pump and external auxiliary fluid pump,...
Adapt Function Automatic - part 2      Inslow adaptive, the TCM still is evaluating shifts and changingadaptive values, but is only allowed to do so in smallerincrements. When a shift switches from fast to slow adaptive mode,it is described as converged. It is...
Adapt Function Automatic      The transmission control module-(TCM) producesexcellent shift quality by applying closed loop control thatconstantly adjusts shift characteristics for changes in operatingconditions. These adjustments are based on vehicle...
Transmission Gear Ratio Manual      Transmission Gear Ratio 1st 2nd 3rd 4th 5th Reverse 3.82 2.31 1.42 1.00 0.83 3.82
Shift Speed Automatic      Shift Speed – 5.3L and 4.8L, 3.42:1 FinalDrive 5.3L (LY5, LMG, LC9) 4.8L (LY2) 3.42:1 Final Drive Percent Throttle Trans Cal. 12.5 25 50 75 100 Normal (Default) Km/h mph Km/h mph Km/h mph Km/h mph Km/h...
Line Pressure Automatic      Line Pressure (4L60-E) Pressure Control Solenoid Current (Amp) Approximate Line Pressure (PSI) 2.9-L/3.7-L 0.00 170–193 0.10 169–192 0.20 168–188 0.30 156–184 0.40 146–176...
Lubrication Specifications Manual      Lubrication Specifications Application Metric English 5W-30 Synthetic OilP/N-ET-M99 3.5-L 3.7-qt
Fluid Passages Automatic      Figure 1: Pump Body Fluid Passages (Pump Cover Side) Figure 2: Pump Cover Fluid Passages (Pump Body Side) Figure 3: Pump Cover Fluid Passages (Case Side) Figure 4: Case Fluid Passages (Pump Cover Side)...
End Play Specifications Automatic      End Play Specifications Application Maximum End Play Metric English New Torque Converter 0.800-mm 0.0310-in Used Torque Converter 1.200-mm 0.0472-in Input Carrier and Thrust Washer 1.010-mm...
Fastener Tightening Specifications - 4WD Driveline Control Automatic      Fastener Tightening Specifications Description of Usage Ref No.* Qty Size Specification Metric English Accumulator Cover to Case 58 1 M6x1.0x65 8–14-Y 71–124-lb-in Accumulator Cover to Case...
Shift Solenoid Valve State and Gear Ratio Automatic Transmission Unit Transmission Shift Solenoids      Shift Solenoid Valve State and Gear Ratio Gear Shift SOL 1 Shift SOL 2 Aux Line BOOST Valve PC SOL 5 N.L. 1–3 CL PC SOL 4 N.L. Hybrid Low, 1–2 CL PC SOL 3 N.H. Hybrid Direct, 2–3–4 CL PC SOL 2N.H. Isolator Valve PC...
Fastener Tightening Specifications (Off Vehicle) Automatic      Fastener Tightening Specifications Application Ref No.* Quantity Size Specification Metric English Case Extension to Case Assembly 16 6 M10x1.5x40 55-Y 41-lb-ft Control Solenoid Valve Assembly...
Fastener Tightening Specifications - 4WD Driveline Control Manual      Fastener Tightening Specifications Application Specification Metric English Anchor Support Screw 28-Y 21-lb-ft Backup Lamp Switch 19-Y 14-lb-ft Bearing Retainer Screw 22-Y 16-lb-ft...
Transmission General Specifications Automatic Transmission Unit      Table 1: Transmission Weight Table 2: Transmission Gear Ratio Table 3: Torque Converter Clutch Pressure Control Solenoid (TCC PCS)Specifications Table 4: Shift Solenoid-1-(SS1), SS2, and SS3Specifications...
Adhesives Fluids Lubricants and Sealers Automatic      Adhesives, Fluids, Lubricants, and Sealers Application Type of Material GM Part Number United States Canada Automatic Transmission Fluid DEXRON®VI 88861037 19264717
Fastener Tightening Specifications (On Vehicle) Automatic      Fastener Tightening Specifications Application Specification Metric English Auxiliary Fluid Cooler Bolts 12-Y 106-lb-in Floor Shift Control Indicator Screw 2.5-Y 22-lb-in Floor Shift Control...
Component Resistance Automatic      Component Resistance Component Pass Thru Pins Resistance at 20°C (68°F) Resistance at 100°C (212°F) Resistance to Ground (Case) 1-2 Shift Solenoid Valve A, E 19–24-? 24–31-? Greater than 250-K-? 2-3...
Reset Transmission Adapts Automatic Transmission Unit      The Reset Transmission Adapts is a procedure for automatictransmissions in which the shift pressure learn values of eachindividual clutch is reset to zero or a base calibrated value, inthe transmission control module-(TCM)....
Transmission Adaptive Functions Automatic Transmission Unit      The transmission utilizes a line pressure control systemduring upshifts to compensate for the normal wear of transmissioncomponents. As the apply components within the transmission wear orchange over time, shift time (the time...
Temperature Versus Resistance (Solenoid) Automatic      Temperature Versus Resistance Sump Temperature Sump Temperature Pressure Control Solenoids 1, 2, MAIN MOD, and TCCResistance Shift Solenoids 1, 2, and 3 °C °F ? ? 0 32 4.4–4.9 19.3–21.3 20 68...
Transmission Identification Information Automatic Transmission Unit      Figure 1: Nameplate Location Figure Transmission Identification Information Figure 2: Nameplate Figure Transmission Identification Information
Transmission Internal Mode Switch Logic Automatic Transmission Unit      Transmission Internal Mode Switch Logic Gear Selector Position Signal A Signal B Signal C Signal P Park (P) LOW HI HI LOW Reverse (R) LOW LOW HI HI Neutral (N) HI LOW HI...
FastLearn Procedure Automatic      Overview In general, FastLearn is a procedure for Allison1000-Series transmissions in which a series of tests arerun to allow the transmission control module-(TCM) tolearn individual clutch characteristics. Once the clutch...
Transmission Fluid Pressure Switch Logic Automatic      Transmission Fluid Pressure (TFP) Switch Logic Gear TFP Switch States TFP SW1 *TFP SW3 TFP SW4 TFP SW5 Park High Low Low Low Reverse Low Low Low Low Neutral High Low Low...
Torque Converter Housing Low and Reverse Clutch Housing Bolt Size Caution Automatic Torque Converter      Caution:The bolts used to install the torque converter housing andthe low and reverse clutch housing to the transmission case aresimilar in size and color. The low and reverse clutch housing boltsare, however, shorter than the...
Case Porosity Repair Automatic      Some external leaks are caused by case porosity innon-pressurized areas. You can usually repair these leaks with thetransmission in the vehicle. Thoroughly clean the area to be repaired with a cleaningsolvent. Air dry the...
Fastener Tightening Specifications - 4WD Driveline Control Manual      Fastener Tightening Specifications Application Specification Metric English Backup Lamp Switch 16–22-Y 12–16-lb-ft Breather Support Screw 13–18-Y 10–14-lb-ft Clutch Actuator Bolts 8-Y...
Transmission Mount Inspection Transmission Mounts      Caution:In order to avoid oil pan damage and possible engine failure,insert a block of wood that spans the width of the oil pan bottombetween the oil pan and the jack support. Raise the transmission/transaxle in order to...
Range Reference Automatic      Range Reference Table Range Park Reverse Neutral Drive 1st Braking 1st 2nd 3rd 4th 5th 6th 1–2–3–4 Clutch — — — Applied Applied Applied Applied Applied — — 3–5 Reverse...
Bushing and Mating Shaft Inspection Automatic      Note:Proper bushing and corresponding mating shaft inspectionshould be performed before replacing the bushing, shaft, and insome cases, the component which houses the bushing. Thoroughlyclean and dry the bushing and shaft...
Definitions and Abbreviations Automatic - part 2      Tie-Up A condition where two opposing clutch and/or bands areattempting to apply at the same time causing the engine to laborwith a noticeable loss of engine RPM. Noise ConditionsDrive Link Noise A whine or growl that increases...
Definitions and Abbreviations Automatic      Throttle PositionsEngine Braking A condition where the engine is used to slow the vehicle bymanually downshifting during a zero throttle coastdown. Full Throttle Detent Downshift A quick apply of the accelerator pedal to its...
Shift Solenoid Valve State and Gear Ratio Automatic Transmission Unit Transmission Shift Solenoids      Shift Solenoid Valve State and Gear Ratio Gear Shift SOL 1 Shift SOL 2 1–2–3–4 CL PC SOL 5 N.L. 2–6 CL PC SOL 4 N.L. 3–5 REV CL PC SOL 2 N.H. LOW REV 4–5–6 CL PC SOL 3 N.H. 6L45 6L50 Gear Ratio 6L80 6L90 Gear Ratio...
Fastener Tightening Specifications (Off Vehicle) Automatic      Fastener Tightening Specifications Application Ref No. * Quantity Size Specification Metric English A/Trans Auxiliary Fluid PumpBolt-–-to Torque DampenerHousing 5 4 M6-x-1.0-x-65 9–13-Y...
Shift Speed (3-4 4-5 5-6 and CT Downshifts) Automatic      Shift Speed - 3–4 Shift Output Shaft RPM 4–5 Shift Output Shaft RPM 5–6 Shift Output Shaft RPM Closed Throttle Downshift Output Shaft RPM - - - - 6–5 5–4 4–3 3–2 2–1 Engine % of TPS 12 25 50 12 25 50...
Fluid Capacity Specifications Automatic      Application Specification Metric English Drain Plug Only– Approximate Capacity 9.93-liters 10.5-quarts Drop Pan and Filter– Approximate Capacity 10.88-liters 11.5-quarts Dry Transmission...
Fluid Passages Automatic      Figure 1: Torque Dampener Housing Assembly Figure 2: Fluid Pump Cover Assembly - Torque Dampener Housing Assembly Side Figure 3: Fluid Pump Cover Assembly - Case Assembly Side Figure 4: Case Assembly -...
Transmission Adaptive Functions Automatic Transmission Unit      The Hydra-Matic® 6–Speed RWD transmissionutilizes a line pressure control system during upshifts tocompensate for the normal wear of transmission components. As theapply components within the transmission wear or change over...
Shift Speed (1-2 and 2-3 Shifts) Automatic      Shift Speed - 1–2 Shift Output Shaft RPM 2–3 Shift Output Shaft RPM Engine % of TPS 12 25 50 100 12 25 50 100 Mode - - LML 6.6L Normal 425 450 722 N/A* 867 867 1199 N/A*...
Reset Transmission Adapts Automatic Transmission Unit      Reset Transmission Adapts is a procedure for automatictransmissions in which a series of tests are run to allow thetransmission control module-(TCM) to learn individualclutch characteristics. Once the clutch data is learned,...
Tow Haul Mode Description and Operation Automatic      Tow/haul mode is a function within the vehicle'ssoftware/calibration that optimizes transmission gear selection foroperation during towing or with heavy loads. This optimizationincludes improving acceleration performance...
Hydraulic Clutch System Bleeding Manual Clutch      Caution:DO NOT use fluid which has been bled from a hydraulic clutchsystem, in order to fill the clutch master cylinder reservoir, dueto the possibility that the fluid may be aerated, have too muchmoisture content, or be...
Clutch Backing Plate Retaining Ring Specifications Automatic      Table 1: 3–5 Reverse Clutch Table 2: 1–2–3–4 Clutch Table 3: 4–5–6 Clutch Table 4: Low/Reverse Clutch 3–5 Reverse Clutch Clutch Pack Travel Specification –1.21–1.79-mm(0.048–0.070-in) Retaining Ring...
Disassembled Views Manual      Figure 1: Transmission Case and Related Components Figure 2: Main Shaft and Components Figure 3: Input Shaft and Components Figure 4: Counter Gear Shaft and Components Figure 5: Shift Control and...
Transmission Component and System Description Automatic Transmission Unit      The mechanical components of the 4L60-E are asfollows: A torque converter with an electronically controlled capacityclutch-(ECCC) This transmission is equipped with an ECCC. The pressureplate does not fully lock to the torque...
Transmission Component and System Description Automatic Transmission Unit      The mechanical components of the 6-Speed RWD are asfollows: A torque converter with an electronically controlled capacityclutch-(ECCC). ECCC was developed to reduce thepossibility of noise, vibration, or chuggle caused by TCC...
Transmission General Description Automatic Transmission Unit      Allison 1000 Series transmissions are torque converterdriven, fully automatic, transmission systems. The 1000 Seriestransmissions have 6-forward speeds, NEUTRAL, andREVERSE. The fifth and sixth range has overdrive gear ratio....