TRANSMISSION Automatic Transmission - VT40 (MRG) - Repair Instructions - Off Vehicle - Trailblazer
TRANSMISSION Automatic Transmission - VT40 (MRG) - Repair Instructions - Off Vehicle - Trailblazer
TRANSMISSION Automatic Transmission - VT40 (MRG) - Repair Instructions - Off Vehicle - Trailblazer
WARNING:
Handle with
care, the
transmission
assembly
weighs over
90.7 kg (200
lbs). Bodily
injury could
occur if not
handled
properly.
Procedure
1. Raise the transmission with an overhead hoist in order to install the holding fixture.
CAUTION:
Refer to
Fastener
Caution .
Tighten
Special Tools
Procedure
1
1. Rotate transmission with pan facing upwards.
2. Remove the bolts completely.
NOTE:
The control
valve body
Callout Component Name
cover seal is
reusable.
Inspect the
seal to
determine if
it may be
reused.
Control Valve Body Cover Wiring Connector Hole Seal
6 Procedure
Remove and DISCARD the seal.
7 Automatic Transmission Fluid Level Control Valve
Automatic Transmission Fluid Level Control Valve Seal
8 Procedure
Remove and DISCARD the seal.
Fig. 3: Exploded View Of Control Valve Solenoid Body Components And Bolt Identification
Courtesy of GENERAL MOTORS COMPANY
NOTE:
The seal is
6 reusable,
inspect the
seal and
replace if
damaged.
7 Control Valve Solenoid Body
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
1 component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
Procedure
Remove and DISCARD the bolt.
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
2 Automatic Transmission Input Speed Sensor
NOTE:
The torque
converter
housing
gasket is
reusable.
Inspect the
gasket to
determine if
it may be
reused. If the
gasket is
stuck to the
Callout Component Name
case or
torque
converter
housing, it
should be
replaced.
5 Transmission Case Locating Pin [2x]
6 Drive Sprocket Thrust Washer
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
Procedure
Remove and DISCARD the bolt.
Special Tools
Callout Component Name
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
Automatic Transmission Output Speed Sensor
Procedure
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
Callout Component Name
damage to
the vehicle
or
component.
Procedure
Remove and DISCARD the bolt.
Special Tool
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
2 Front Differential Carrier Baffle
NOTE:
The forward
clutch may
come out
with
automatic
transmission
2 fluid pump.
Procedure
CAUTION:
Callout Component Name
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
Procedure
Remove and DISCARD the bolt.
Special Tool
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
Automatic Transmission Intermediate Speed Sensor
Procedure
2
1. Disconnect the intermediate speed sensor connector.
2. Remove the intermediate speed sensor.
MANUAL SHIFT DETENT LEVER WITH SHAFT POSITION SWITCH ASSEMBLY AND PARK
PAWL ACTUATOR REMOVAL
Fig. 7: Exploded View Of Manual Shift Detent Lever With Manual Shift Detent Lever Spring And Park
Pawl Actuator Components
Courtesy of GENERAL MOTORS COMPANY
Manual Shift Detent Lever with Manual Shift Detent Lever Spring and Park Pawl Actuator Removal
Callout Component Name
Manual Shift Detent Spring Bolt M6 x 25.65
1 Procedure
Remove and DISCARD the bolt.
2 Manual Shift Detent Lever Spring
Manual Shift Detent Lever Hub Pin
Procedure
3
1. Use a punch from the top to remove the pin.
2. Remove and DISCARD, pin is not reusable.
CAUTION:
Do not
damage the
case bore
during
removal of
the manual
shift shaft
seal.
Procedure
Callout Component Name
1. Use the DT-52322 Seal Remover to remove the seal to prevent damage to the case
surface.
2. Remove and DISCARD the seal.
Special Tools
DT-52322 Seal Remover
Equivalent regional tools: Special Tools
Special Tools
1
DT-23129 Universal Seal Remover
GE-6125-1B Slide Hammer
CAUTION:
After
cleaning the
transmission
components,
allow to air
dry. Do not
use cloth or
paper towels
in order to
dry any
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary Procedures
1. Thoroughly clean the transmission case assembly, including case threads, with clean solvent.
2. Clean gasket sealing surfaces. Remove all residual gasket material.
3. Inspect all threaded holes. If necessary, repair any thread damage.
NOTE:
1
The locating
pins
installed
height is 7.4
mm (0.29 in).
2 Torque Converter and Differential Housing Sealing Surface
3 Control Valve Body Cover Sealing Surface
4 Automatic Transmission Case Hole Plug [4x]
Callout Component Name
CAUTION:
Refer to
Fastener
Caution .
Tighten
10.5 N.m (93 lb in)
5 Control Valve Body Locating Pin
6 Manual Shift Shaft Seal Surface
7 Transmission Fluid Filler Cap
Transmission Fluid Filler Cap Seal
8 Procedure
Remove and DISCARD the seal.
9 Transmission Fluid Filler Cap Sealing Surface
10 Automatic Transmission Intermediate Speed Sensor Sealing Surface
Automatic Transmission Case Cover Plug
11 Tighten
10.5 N.m (93 lb in)
Automatic Transmission Case Cover Plug [2x]
12 Tighten
16 N.m (12 lb ft)
CAUTION:
Failure to
apply the
lubricant will
cause
damage to
the bolt and
nut threads.
Callout Component Name
Procedure
Tighten DT-50712 Bearing Cup Remover until it fits snugly on the bearing cup.
Adjust J-45124 Removal Bridge so it sits on the case surface just beyond the bearing
cup opening.
Apply the extreme pressure lubricant DT-23444-A Extreme Press Lubricant to the
puller bolt threads to prevent damage to the bolt threads during bearing cup removal.
Hold the puller bridge nut and turn the nut to remove the bearing cup.
Special Tools
CAUTION:
Support the
back side of
the case
before
installing the
bearing cup.
Apply a light
coating of
transmission
Callout Component Name
fluid to the
bore before
pressing the
cup into
position.
Install the
bearing cup
until it stops
moving.
Applying
excessive
pressure to
the bearing
cup once it
is seated
could cause
damage to
the case
casting.
CAUTION:
An unseated
or
improperly
installed
bearing cup
will result in
premature
bearing
failure.
Visually
inspect the
bearing cup
to insure
there is "no
gap"
between the
case, thrust
washer, and
the bearing
cup. Use of a
feeler gauge
may assist
in identifying
a bearing
cup that is
not fully
seated.
Procedure
Use a press with J-44908 Bearing Cup Installer to install the front differential bearing
cup.
Special Tools
Callout Component Name
J-44908 Bearing Cup Installer
Equivalent regional tools: Special Tools
CAUTION:
Failure to
apply the
lubricant will
cause
damage to
the bolt and
nut threads.
Procedure
Tighten DT-50711 Cup Remover until it fits snugly on the bearing cup.
1 Adjust DT-45124 Removal Bridge so it sits on the case surface just beyond the bearing
cup opening.
Apply the extreme pressure lubricant DT-23444-A Extreme Press Lubricant - 1/4
Ounce Tube to the puller bolt threads to prevent damage to the bolt threads during
bearing cup removal.
Hold the puller bridge nut and turn the bolt to remove the bearing cup.
Special Tools
CAUTION:
Support the
back side of
the case
before
installing the
bearing cup.
Apply a light
coating of
transmission
fluid to the
bore before
pressing the
cup into
position.
Install the
bearing cup
until it stops
moving.
Applying
excessive
pressure to
the bearing
cup once it
is seated
could cause
damage to
the case
casting.
CAUTION:
Callout Component Name
An unseated
or
improperly
installed
bearing cup
will result in
premature
bearing
failure.
Visually
inspect the
bearing cup
to insure
there is "no
gap"
between the
case, thrust
washer, and
the bearing
cup. Use of a
feeler gauge
may assist
in identifying
a bearing
cup that is
not fully
seated.
Procedure
Use a press with J-46464 Bearing Cup Installer to install the front differential drive
pinion gear bearing cup.
Special Tools
J-46464 Bearing Cup Installer
Equivalent regional tools: Special Tools
Special Tools
1
DT-50896 Front Wheel Drive Shaft Oil Seal Installer
J-22828 Tube Driver
MANUAL SHIFT DETENT LEVER WITH SHAFT POSITION SWITCH ASSEMBLY AND PARK
PAWL ACTUATOR INSTALLATION
Fig. 9: Exploded View Of Manual Shift Detent Lever With Manual Shift Detent Lever Spring And Park
Pawl Actuator Components
Courtesy of GENERAL MOTORS COMPANY
Manual Shift Detent Lever with Manual Shift Detent Lever Spring and Park Pawl Actuator Installation
Callout Component Name
1 Manual Shift Detent Lever
2 Park Pawl Actuator
3 Manual Shift Detent Lever Shaft
Procedure
Callout Component Name
Lubricate the shaft with ATF to prevent damage to the manual shift shaft seal during
installation.
Manual Shift Detent Lever Hub Pin
CAUTION:
Refer to
Fastener
Caution .
4 Procedure
Specification
7.9 mm (0.38 in) (a)
5 Manual Shift Detent Lever Spring
Manual Shift Detent Spring Bolt M6 x 25.65
Procedure
6 Install NEW bolts. Do NOT reuse old bolts.
Tighten
9 N.m (80 lb in)
CAUTION:
When
installing the
seal, ensure
the seal lip
is firmly
seated
against the
case bore
surface. Do
not allow the
Callout Component Name
seal lip to be
crushed, or
a leak may
result.
Procedure
Install a NEW seal. Do NOT reuse the old seal.
Special Tools
DT-51672 Manual Shaft Seal Installer
Equivalent regional tools: Special Tools
1. Use J-45201 Cooler Line Seal Remover to remove the transmission fluid cooler pipe
fitting seal.
1 2. Remove and DISCARD the seal.
Special Tools
J-45201 Cooler Line Seal Remover
Equivalent regional tools: Special Tools
1. Use DT-47770 Cooler Line Seal Installer to install the transmission fluid cooler pipe
fitting seal. Install seal flush or up to 0.3 mm (a) below flush.
1 2. Install a NEW seal. Do NOT reuse the old seal.
Special Tools
DT-47770 Cooler Line Seal Installer
Equivalent regional tools: Special Tools
NOTE:
Callout Component Name
To prevent
damage to
the seal
during
installation,
apply
assembly
grease to the
harness
connector
prior to
installation.
NOTE:
2 Ensure all
retaining
clips are
installed
properly.
Wiring Harness Bracket Bolt [3x] M6 x 25
CAUTION:
Refer to
3 Fastener
Caution .
Tighten
9 N.m (80 lb in)
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
2 torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
Procedure
Install a NEW bolt. Do NOT reuse the old bolt.
Tighten
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
NOTE:
Ensure the
6 retaining
ring is
engaged
fully under
slotted
covering.
NOTE:
1
Ensure
spring is
centered.
Reverse Clutch Spring Retaining Ring
Procedure
NOTE:
Ensure the
retaining
ring is
engaged
fully under
slotted
2
covering.
1. Use the DT-52315 Reverse Clutch Spring Compressor to install the reverse clutch
spring retaining ring.
2. Apply downward pressure to the reverse clutch spring to allow the reverse clutch
spring retaining ring to seat fully in groove.
Special Tools
DT-52315 Reverse Clutch Spring Compressor
Equivalent regional tools: Special Tools
CAUTION:
Do not use
old seal
rings. Install
NEW seal
rings.
Reusing old
seal rings
may cause
internal
transmission
leaks and
transmission
damage.
CAUTION:
Size the fluid
seal rings
for at least 5
minutes
after
installation
to obtain
proper seal
ring size.
Callout Component Name
Failure to do
so may
cause
internal
transmission
leaks and
transmission
damage.
Procedure
Install NEW seals. Do NOT reuse old seals.
Special Tools
DT-52314 Turbine Shaft Seal Installer
Equivalent regional tools: Special Tools
Turbine Shaft Seal
2 Procedure
Install NEW seals. Do NOT reuse old seals.
NOTE:
The fluid
8 pump
pressure
plate may be
stuck in the
fluid pump
body.
Callout Component Name
Automatic Transmission Fluid Pump Pressure Plate Seal
9 Procedure
Remove and DISCARD the seal.
10 Automatic Transmission Fluid Pump Shaft
11 Automatic Transmission Fluid Pump Cam
12 Automatic Transmission Fluid Pump Thrust Plate
13 Auxiliary Control Valve Body Spacer Plate
CAUTION:
After
cleaning the
transmission
components,
allow to air
dry. Do not
Callout Component Name
use cloth or
paper towels
in order to
dry any
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary ProceduresClean and inspect all valve components for wear and/or damage.
1 Automatic Transmission Fluid Pump Clip
2 Automatic Transmission Fluid Drain Ball Check Valve
3 Torque Converter Clutch Blowoff Ball Valve Retainer
4 Torque Converter Clutch Blowoff Ball Valve Spring
5 Torque Converter Clutch Blowoff Ball Valve
Automatic Transmission Fluid Pump Seal
NOTE:
6 Not
serviceable,
do not
remove seal.
Fig. 16: Exploded View Of Transmission Fluid Pump Components For Cleaning And Inspection (2 Of 2)
Courtesy of GENERAL MOTORS COMPANY
CAUTION:
After
cleaning the
transmission
components,
allow to air
dry. Do not
Callout Component Name
use cloth or
paper towels
in order to
dry any
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary ProceduresClean and inspect all valve components for wear and/or damage.
1 Body Valve Bore Plug Retainer
2 Body Valve Bore Plug
3 Binary Switching Valve
4 Binary Switching Valve Spring
5 Automatic Transmission Fluid Pump Pressure Relief Valve Bore Plug
6 Automatic Transmission Fluid Pump Pressure Relief Valve Spring
7 Automatic Transmission Fluid Pump Pressure Relief Valve
Automatic Transmission Fluid Pump Shaft Seal
NOTE:
8 Not
serviceable,
do not
remove seal.
CAUTION:
Refer to
Fastener
Callout Component Name
Caution .
Tighten
10 N.m (89 lb in)
Automatic Transmission Fluid Pump Cover Bolt [2x] M6 x 30
13 Tighten
10 N.m (89 lb in)
Fig. 18: Exploded View Of Drive Link, Drive Sprocket And Driven Sprocket Components
Courtesy of GENERAL MOTORS COMPANY
CAUTION:
Do not use
old seal
rings. Install
NEW seal
rings.
Reusing old
seal rings
may cause
internal
transmission
leaks and
transmission
damage.
Callout Component Name
CAUTION:
Size the fluid
seal rings
for at least 5
minutes
after
installation
to obtain
proper seal
ring size.
Failure to do
so may
cause
internal
transmission
leaks and
transmission
damage.
Procedure
Use the seal pusher and sizer from DT-51191 Pump Seal Installer Set along with the DT-
51191-4 Stator Shaft Seal Protector to install the torque converter fluid seal ring.
Special Tools
CAUTION:
Refer to
3 Fastener
Caution .
Tighten in sequence
12 N.m (106 lb in)
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
CAUTION:
Refer to
Fastener
Caution .
Procedure
Install a NEW bolt. Do NOT reuse the old bolt.
Tighten
Callout Component Name
1. First Pass: 4 N.m (35 lb in)
2. Final Pass: 45 degrees
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
Callout Component Name
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
CAUTION:
Refer to
Fastener
Caution .
Procedure
Install a NEW bolt. Do NOT reuse the old bolt.
Tighten
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
CAUTION:
Do not reuse
cleaning
Callout Component Name
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
CAUTION:
Keep the
thrust
washers
with gear it
was
matched to.
The thrust
washers are
selective
sizes and it
is difficult to
identify the
proper
washer
thickness.
Improper
assembly
can cause
premature
failure of the
differential
assembly.
Preliminary ProcedureClean and inspect the differential assembly, pinion gears and thrust washers for
scoring, wear or damage. The differential assembly is only serviced as an assembly.
Front Differential Pinion Gear Shaft Retainer
Procedure
1
Remove the retainer using a 3/16 in (5 mm) diameter 7 in punch or equivalent. Discard and
use a new retainer
2 Front Differential Pinion Gear Shaft
3 Front Differential Pinion Gear
4 Front Differential Carrier Thrust Washer
5 Front Differential Pinion Side Gear
6 Front Differential Side Gear Thrust Washer
Procedure
1. Cut in the outer bearing cage of the upper main shaft in several places on the top using
1 side cutting pliers.
2. Cut in the outer bearing cage of the upper main shaft in several places on the bottom,
using side cutting pliers. If necessary, use a screwdriver to lift the cage.
3. Remove and DISCARD the cage and all rollers.
2 Inner Race
Procedure
1. Install the DT-22912-B Bearing Remover to the outer bearing inner ring of the upper
main shaft, make sure of proper seat (arrow).
2. Tighten 4 nuts of the DT-22912-B Bearing Remover.
3. Attach J-8433 Puller Bar to DT-22912-B Bearing Remover using two 3/8 x 24 x 3 inch
bolts.
4. Remove the outer bearing inner ring from the upper main shaft using J-47965-2
Centering Pilot.
NOTE:
Use two 3/8
x 24 x 3 inch
bolts with J-
8433 Puller
Bar.
Special Tools
NOTE:
Use two 3/8
x 24 x 3 inch
bolts with J-
8433 Puller
Bar.
3
Special Tools
CAUTION:
Pressing
against the
bearing
assembly
can damage
the bearing
Callout Component Name
and cause
premature
bearing
failure.
Using J-25234 Gear and Bearing Installer and an arbor press, install the front differential
carrier bearing.
Special Tools
J-25234 Gear and Bearing Installer
Equivalent regional tools: Special Tools
Front Differential Carrier Bearing
Procedure
CAUTION:
Pressing
against the
bearing
assembly
can damage
the bearing
2 and cause
premature
bearing
failure.
Using J-25234 Gear and Bearing Installer and an arbor press, install the front differential
carrier bearing.
Special Tools
J-25234 Gear and Bearing Installer
Equivalent regional tools: Special Tools
FRONT DIFFERENTIAL DRIVE PINION GEAR WITH TRANSFER GEAR 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
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary ProcedureClean and inspect the front differential drive pinion gear with transfer gear
assembly for scoring, wear or damage. The front differential drive pinion gear with transfer gear is only
Callout Component Name
serviced as an assembly.
Front Differential Drive Pinion Gear Bearing
NOTE:
1
Bearing is
not
serviceable.
2 Front Differential Drive Transfer Gear
3 Front Differential Drive Pinion Gear
4 Front Differential Drive Pinion Gear Bearing
NOTE:
Use two 3/8
x 24 x 3 inch
bolts with J-
8433 Puller
Bar
1
Special Tools
NOTE:
Pressing
against the
bearing
assembly
can damage
1 the bearing
and cause
premature
bearing
failure.
Special Tools
J-8107-4 Gear and Bearing Installer
Equivalent regional tools: Special Tools
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
Callout Component Name
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
Procedure
Remove and DISCARD the bolt.
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
2 Front Differential Carrier Baffle
FRONT WHEEL DRIVE SHAFT OIL SEAL REMOVAL - TORQUE CONVERTER AND
DIFFERENTIAL HOUSING SIDE
Special Tools
1
DT-23129 Universal Seal Remover
GE-6125-1B Slide Hammer
Special Tools
1
DT-6125-B Slide Hammer
EN-23129 Universal Seal Remover
CAUTION:
Callout Component Name
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
CAUTION:
Do not use
abrasive
pads or
bristle
devices to
clean the
sealing
surfaces.
Abrasive
pads
produce a
fine grit that
can effect
transmission
function.
Abrasive
pads can
also remove
enough
metal to
create oil
leaks.
Preliminary ProceduresThoroughly clean the torque converter housing, including case threads with clean
solvent.
1 Threaded Hole
2 Threaded Hole
3 Gasket Sealing Surface
4 Transmission Fluid Filler Hole Plug
Automatic Transmission Case Hole Plug [2x]
CAUTION:
Refer to
5 Fastener
Caution .
Tighten
10.5 N.m (93 lb in)
6 Vent Pipe
FRONT DIFFERENTIAL CARRIER BEARING CUP OVERHAUL - TORQUE CONVERTER AND
DIFFERENTIAL HOUSING SIDE
CAUTION:
Failure to
apply the
lubricant will
cause
damage to
the bolt and
nut threads.
Procedure
1. Tighten DT-50712 Bearing Cup Remover until it fits snugly on the bearing cup.
1 2. Adjust DT-45124 Removal Bridge so it sits on the torque converter housing surface
just beyond the bearing cup opening.
3. Apply the extreme pressure lubricant DT-23444-A Extreme Press Lubricant - 1/4
Ounce Tube to the puller bolt threads to prevent damage to the bolt threads during
bearing cup removal.
4. Hold the puller bridge bolt and turn the nut to removal the bearing cup.
Special Tools
CAUTION:
Support the
back side of
the torque
converter
housing
before
installing the
bearing cup.
Apply a light
coating of
transmission
fluid to the
bore before
pressing the
cup into
position.
Install the
bearing cup
until it stops
moving.
Applying
excessive
pressure to
the bearing
cup once it
is seated
could cause
damage to
the torque
Callout Component Name
converter
housing
casting.
CAUTION:
An unseated
or
improperly
installed
bearing cup
will result in
premature
bearing
failure.
Visually
inspect the
bearing cup
to insure
there is "no
gap"
between the
case, thrust
washer, and
the bearing
cup. Use of a
feeler gauge
may assist
in identifying
a bearing
cup that is
not fully
seated.
Special Tools
J-44908 Bearing Cup Installer
Equivalent regional tools: Special Tools .
CAUTION:
Failure to
apply the
lubricant will
cause
damage to
the bolt and
nut threads.
Procedure
1. Tighten DT-50711 Bearing Cup Remover until it fits snugly on the bearing cup.
1 2. Adjust DT-45124 Removal Bridge so it sits on the torque converter housing surface
just beyond the bearing cup opening.
3. Apply the extreme pressure lubricant DT-23444-A Extreme Press Lubricant - 1/4
Ounce Tube to the puller bolt threads to prevent damage to the bolt threads during
bearing cup removal.
4. Hold the puller bridge bolt and turn the nut to removal the bearing cup.
Special Tools
CAUTION:
Support the
back side of
the torque
converter
housing
before
installing the
bearing cup.
Apply a light
coating of
transmission
fluid to the
bore before
pressing the
cup into
position.
Install the
bearing cup
until it stops
moving.
Applying
excessive
pressure to
the bearing
cup once it
is seated
could cause
damage to
the torque
converter
housing
casting.
CAUTION:
An unseated
or
improperly
installed
bearing cup
will result in
premature
bearing
failure.
Visually
inspect the
bearing cup
to insure
there is "no
Callout Component Name
gap"
between the
case, thrust
washer, and
the bearing
cup. Use of a
feeler gauge
may assist
in identifying
a bearing
cup that is
not fully
seated.
Special Tools
DT-46464 Bearing Cup Installer
Equivalent regional tools: Special Tools .
FRONT DIFFERENTIAL DRIVE PINION GEAR BEARING SHIM AND FRONT DIFFERENTIAL
CARRIER BEARING SHIM MEASUREMENT
Fig. 22: Exploded View Of Front Differential Drive Pinion Gear Bearing Shim And Front Differential
Carrier Bearing Shim Measurement Components
Courtesy of GENERAL MOTORS COMPANY
Differential Shim Selection Gauge Installation
Callout Component Name
Front Differential Carrier
Procedure
1
Install the Front Differential Carrier and the Front Differential Drive Pinion Gear together to
avoid interference with the gears during installation.
Front Differential Drive Pinion Gear
Procedure
2
Install the Front Differential Carrier and the Front Differential Drive Pinion Gear together to
avoid interference with the gears during installation.
Front Differential Drive Pinion Gear Bearing Cup
Procedure
1. Place the bearing cup on the front differential drive pinion Gear bearing.
3 2. Place DT-52318-1 onto the bearing cup.
Special Tools
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
Front Differential Carrier Bearing Cup
Procedure
Special Tools
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
5 Torque Converter Housing Gasket
6 Torque Converter and Differential Housing
Procedure
1. Install two DT-52318-6 guide pins into a case threaded hole at approximately 180
degrees apart.
2. Install DT-52318-3 spacer over each DT-52318-6.
3. Lower the TC housing onto the case.
NOTE:
Some
alignment of
DT-52318-1
and 2 may
be required
while
lowering the
TC housing
onto the
case.
Special Tools
Callout Component Name
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
Fig. 23: Identifying Torque Converter And Differential Housing Components And Spacer Bolts With
Tightening Sequence
Courtesy of GENERAL MOTORS COMPANY
Torque Sequence
Callout Component Name
1 Spacer Bolt [8x]
CAUTION:
Refer to
Fastener
Caution .
NOTE:
The 2 larger
bolts of DT-
52318 Shim
Selection
Gauge Kit
are indicated
by arrows in
Callout Component Name
graphic
inset.
Procedure
1. Install the remaining bolts and spacers evenly at every other bolt hole.
2. Remove the two DT-52318-6 guide pins and install spacer bolts in those locations.
Tighten in sequence
30 N.m (22 lb ft)
Special Tools
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
Front Differential Carrier Assembly
CAUTION:
If the
bearings are
not properly
seated into
the bearing
cups, the
washer
selection will
be
inaccurate
and the
2 bearing pre-
load will be
set too low.
Low bearing
pre-load will
cause
premature
failure of the
front
differential
drive pinion
gear.
Procedure
Rotate the differential assembly if possible to allow the bearings to seat into the cups.
Differential Shim Selection
Callout Component Name
CAUTION:
Improper
shim
selection
can cause
insufficient
taper
bearing pre-
load, which
will cause
premature
failure of the
front
differential
drive pinion
gear.
1 Front Differential Bearing Shim
Procedure
NOTE:
It may be
necessary to
sandwich
feeler gauges
together to
achieve an
accurate
measurement
in gap.
Callout Component Name
2. Continue trying different sizes of DT-52318-7 until the gauge will no longer fit into the
gap. The correct shim size is equal to the largest blade gauge that fits into the gap.
3. Match the size of the correct DT-52318-7 to the color code in the shim specification
chart. The washer color coding is on the outside diameter of the shim.
4. The gap in DT-52318-2 may not be even. Hold the top of the gauge and rotate the
bottom of the gauge to even out the gap. Take two gap measurements 180 degrees
apart. Average the two measurements and select the shim that is closest to the average.
The shim color coding is on the outside diameter of the shim. Refer to Taper Bearing
Preload Selective Specifications .
Special Tools
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
Front Differential Drive Pinion Gear Bearing Shim
Procedure
Special Tools
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
3 Torque Converter and Differential Housing
NOTE:
DT-52318-1
and DT-
52318-2 may
stick in the
torque
converter
housing. Be
careful not
to drop the
gauges.
Procedure
Special Tools
DT-52318 Shim Selection Gauge Kit
Equivalent regional tools: Special Tools .
FRONT WHEEL DRIVE SHAFT OIL SEAL INSTALLATION - TORQUE CONVERTER AND
DIFFERENTIAL HOUSING SIDE
Callout Component Name
Front Wheel Drive Shaft Oil Seal
Procedure
Install a NEW seal. Do NOT reuse the old seal.
1 Special Tools
DT-50896 Front Wheel Drive Shaft Oil Seal Installer
J-22828 Tube Driver
Equivalent regional tools: Special Tools
NOTE:
1 Ensure
magnet is
cleaned of
all debris.
Callout Component Name
Front Differential Carrier Baffle Bolt [2x] M6 x 25
CAUTION:
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
2 fastener
could cause
damage to
the vehicle
or
component.
CAUTION:
Refer to
Fastener
Caution .
Procedure
Install a NEW bolt. Do NOT reuse the old bolt.
Tighten
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
NOTE:
The torque
converter
housing
gasket is
reusable.
2 Inspect the
gasket to
determine if
it may be
reused. If the
gasket is
stuck to the
case or pan,
it should be
replaced.
3 Drive Sprocket Thrust Washer
4 Torque Converter and Differential Housing
Callout Component Name
Torque Converter and Differential Housing Bolt [13x] M8 x 30
CAUTION:
Refer to
Fastener
Caution .
Procedure
5 Install a NEW bolt. Do NOT reuse the old bolt.
Tighten in sequence
CAUTION:
Callout Component Name
This vehicle
is equipped
with torque-
to-yield or
single use
fasteners.
Install a
NEW torque-
to-yield or
single use
fastener
when
installing
this
component.
Failure to
replace the
torque-to-
yield or
single use
fastener
could cause
damage to
the vehicle
or
component.
CAUTION:
Refer to
Fastener
Caution .
Procedure
Install a NEW bolt. Do NOT reuse the old bolt.
Tighten
Special Tools
DT-48285 Torque Socket
Equivalent regional tools: Special Tools
NOTE:
Inspect the
spacer plate
2 bolt pass
through
holes for
damage or
brinelling.
Replace as
necessary.
3 Control Valve Body Locating Pin [2x]
4 Variable Feed Solenoid Clutch Accumulator Piston [3x]
5 Variable Feed Solenoid Clutch Accumulator Piston Spring [3x]
6 Variable Feed Solenoid Clutch Accumulator Piston [3x]
7 Variable Feed Solenoid Clutch Accumulator Piston Spring [3x]
Fig. 26: Exploded View Of Control Valve Channel Plate Components
Courtesy of GENERAL MOTORS COMPANY
NOTE:
Inspect the
spacer plate
3 bolt pass
through
holes for
damage or
brinelling.
Replace as
necessary.
4 Control Valve Body Ball Check Valve [2x]
5 Control Valve Body Ball Check Valve
6 Control Valve Body Locating Pin [2x]
CAUTION:
After
cleaning the
transmission
components,
allow to air
dry. Do not
use cloth or
Callout Component Name
paper towels
in order to
dry any
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary ProceduresClean and inspect all valve components and the valve body. The control valve
body assembly is only replaceable as an assembly.
1 Control Valve Solenoid Retainer [6x]
2 Shift Solenoid Valve [3x]
3 Shift Solenoid Valve [2x]
4 Shift Solenoid Valve
CAUTION:
After
cleaning the
transmission
components,
allow to air
dry. Do not
Callout Component Name
use cloth or
paper towels
in order to
dry any
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary ProceduresClean and inspect all valve components and the valve body. The control valve
body assembly is only replaceable as an assembly.
1 Variable Driven Pulley Regulator Valve
2 Variable Driven Pulley Regulator Valve Spring
3 Body Valve Bore Plug [3x]
4 Body Valve Bore Plug Retainer [4x]
5 Variable Drive Pulley Regulator Valve Spring
6 Variable Drive Pulley Regulator Valve
7 Torque Converter Clutch Regulator Valve
8 Torque Converter Clutch Regulator Valve Spring
9 Feed Limit Valve Spring
10 Feed Limit Valve
Fig. 29: Exploded View Of Control Valve Body Components For Cleaning And Inspection (2 Of 2)
Courtesy of GENERAL MOTORS COMPANY
CAUTION:
After
cleaning the
transmission
components,
allow to air
dry. Do not
Callout Component Name
use cloth or
paper towels
in order to
dry any
transmission
components.
Lint from the
towels can
cause
component
failure.
CAUTION:
Do not reuse
cleaning
solvents.
Previously
used
solvents
may deposit
sediment
which may
damage the
component.
Preliminary ProceduresClean and inspect all valve components and the valve body. The control valve
body assembly is only replaceable as an assembly.
1 Manual Valve
2 Clutch Regulator Valve Spring
3 Clutch Regulator Valve
4 Body Valve Bore Plug [2x]
5 Body Valve Bore Plug Retainer [5x]
6 Default Override Valve Spring
7 Default Override Valve
8 Torque Converter Clutch Control Valve Spring
9 Torque Converter Clutch Control Valve
10 Torque Converter Clutch Valve Spring
11 Torque Converter Clutch Valve
12 Pressure Regulator Valve Spring
13 Pressure Regulator Valve
14 Pressure Regulator Shuttle Valve
15 Pressure Regulator Valve Bore Bushing
CAUTION:
Refer to
6 Fastener
Caution .
Tighten
8 N.m (71 lb in)
Fig. 31: Exploded View Of Control Valve Body Spacer Plate Components
Courtesy of GENERAL MOTORS COMPANY
Procedure
2
1. Install control valve body on case.
2. Align the manual shift detent lever in the groove of the manual valve.
CAUTION:
Refer to
3 Fastener
Caution .
Tighten
8 N.m (71 lb in)
Fig. 32: Exploded View Of Control Valve Solenoid Body Components And Bolt Identification
Courtesy of GENERAL MOTORS COMPANY
NOTE:
The control
valve body
4 cover seal is
reusable.
Inspect the
seal to
determine if
it may be
used.
5 Control Valve Body Cover
6 Control Valve Body Cover Stud [8x] M6 x 1
Callout Component Name
CAUTION:
Refer to
Fastener
Caution .
Tighten in sequence
9 N.m (80 lb in)
Control Valve Body Cover Bolt [4x] M6 x 30
7 Tighten in sequence
9 N.m (80 lb in)
Automatic Transmission Fluid Level Hole Plug M12 x 1.25
8 Tighten
2 N.m (18 lb in)
CAUTION:
Refer to
Fastener
Caution .
1
Procedure
Install a NEW filter. DO NOT reuse old filter.
Tighten
60 N.m (44 lb ft)
Special Tools
DT-52316 Filter Remove/Install Tool
Equivalent regional tools: Special Tools
CAUTION:
Lower the
torque
converter
straight
down.
Failure to
lower the
torque
1 converter
straight
down could
damage the
torque
converter
clutch lip
seal inside
the torque
converter
clutch
assembly.
WARNING:
Handle with
care, the
transmission
assembly
weighs over
90.7 kg (200
lbs). Bodily
injury could
occur if not
handled
properly.
Procedure
NOTE:
Only 2 bolt
holes on the
lift plate will
align with
the bosses
on the
transmission
case. This is
sufficient for
lifting the
transmission
to remove
the holding
fixture.