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Removal and Replacement

TRANSMISSION REPLACEMENT 4L80-E/4L80-EHD TRANSMISSION

^ Tool Required:
- J 21366 Converter Holding Strap

REMOVE OR DISCONNECT
1. Negative battery cable.
- Raise and support the vehicle.
2. Transmission oil.
3. Shift cable.
4. Propeller shaft from the transmission (two wheel drive only).
- Front propeller shaft from the transfer case (four wheel drive only).
- Transfer case and adapter from the transmission. (four wheel drive only).
- Support the transmission with a transmission jack.





5. Two bolts, two washers, and a nut securing the brace to the engine and transmission.
- The image depicts the left side brace mounting to the engine and transmission. The right side mounting of the brace is similar.





6. Nut and washer securing the transmission mount to the crossmember.
7. Two bolts and washers securing the mount to the transmission.
8. Bolts securing the crossmember to the frame.
9. Starter.
10. Exhaust pipe from the exhaust manifolds and the muffler assembly from the exhaust pipe if required.
11. Oil Level Indicator Tube.
12. Wiring harness connectors from the transmission speed sensor and the park/neutral position switch.
- Remove all vehicle harness wires, harness clips, tubes, brackets, and lines that may interfere with the removal of the transmission from the vehicle.
13. Oil cooler lines from the transmission.
- Plug all openings in the transmission and the oil cooler lines.
14. Transmission vent hose from the transmission.





15. Bolts securing the torque converter cover to the transmission.
- Mark the flywheel and torque converter alignment.
- Note the location of any brackets or clips and move them aside.
16. J 21366 Converter Holding Strap to the converter.
- Position J 21366 converter holding strap onto the torque converter to keep the torque converter from sliding off the turbine shaft.

Important: Ensure that the engine is supported with a jack stand before detaching the transmission from the engine.





17. Studs securing the transmission to the engine.
- Pull the transmission straight back from the engine.
- Lower the transmission using the transmission jack.
18. Transmission from the vehicle.

INSTALL OR CONNECT
1. Transmission to the engine.
- Ensure that the torque converter is seated properly and that the converter holding strap J 21366 is in place.
- Ensure that the transmission is supported with a transmission jack.
- Raise the transmission into place and remove J 21366 while lining up the marks on the flywheel and torque converter.

Important: The torque converter must be flush onto the flywheel and rotate freely by hand.

2. Studs securing the transmission to the engine.
- Tighten transmission to engine studs to 47 Nm (34 lbs. ft.).





3. Position the torque converter to the flywheel.
- Using the reference marks, align the torque converter with the flywheel.
- Ensure the identification hole on the flywheel is aligned with the attachment on the torque converter.
4. Three bolts securing the torque converter to the flywheel.
- Tighten flywheel to torque converter bolts to 44 Nm (33 lbs. ft.).
5. Starter.





6. Bolts securing the torque converter cover to the transmission.
- Tighten torque converter cover bolts to 33 Nm (24 lbs. ft.).
7. Wiring harness connectors to the transmission speed sensor and park/neutral position switch.
- Position/install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal.
8. Transmission cooler lines to the transmission.
- Unplug all of the openings in the transmission and oil cooler lines.
- Do not twist or bend the lines during installation.
9. Oil level indicator tube with a new seal.
- Ensure that the oil level indicator tube plug is removed from the transmission case.
10. Transmission vent hose and wiring harness to the transmission.
- Remove the transmission jack.
11. Bolts securing the crossmember to the frame.
- Tighten bolts to 77 Nm (56 lbs. ft.).





12. Nut and washer securing the transmission mount to the crossmember.
- Tighten bolts to 52 Nm (38 lbs. ft.).
13. Two bolts and washers securing the mount to the transmission.
- Tighten bolts to 47 Nm (35 lbs. ft.).





14. Two bolts, two washers, and a nut securing the brace to the engine and transmission.
- Tighten transmission to engine brace bolts (Gasoline Engine) to 55 Nm (41 lbs. ft.).
- Transmission to engine brace bolts (Diesel Engine) to 70 Nm (51 lbs. ft.).
15. Exhaust pipe to the exhaust manifolds and the muffler assembly to the exhaust pipe if required.
16. Transfer case and adapter to the transmission. (four wheel drive only).
17. Propeller shaft to the transmission (two wheel drive only).
18. Propeller shafts to the transfer case (four wheel drive only).
19. Shift cable to the transmission shift lever.
- Lower the vehicle.
20. New transmission oil.
21. Negative battery cable.
22. Start the engine and check for transmission oil leaks.
23. Test the transmission for normal operation.
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