4L60-E/4T65-E Automatic Transmission

Transmission Replacement
Removal Procedure





Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the battery negative cable assembly from the battery negative terminal.
2. Raise the vehicle. Refer to Vehicle Lifting.
3. Support the vehicle with safety stands.
4. Disconnect the range selector cable from the transmission bracket and from the range selector lever.
5. If equipped with All Wheel Drive (AWD), remove the transfer case.
6. Remove the rear propeller shaft.
7. Support the transmission with a transmission jack.
8. Remove the transmission support.
9. Remove the exhaust pipe from the exhaust manifolds and the muffler assembly from the exhaust pipe.





10. Remove the starter motor.
11. Remove the converter sight shield.
12. Mark the flywheel and the torque converter alignment.





Important: For 4.3L engine, remove the starter opening shield in the starter motor mounting port in order to access the torque converter to engine flywheel bolts.

13. Remove the bolts that attach the torque converter to the engine flywheel.





14. Remove the transmission vent hose and the wiring harness from the transmission.
15. Remove the transmission fluid fill tube and the fill tube seal from the transmission.
16. Plug the fluid fill tube opening in the transmission.
17. Disconnect the transmission oil cooler pipes from the transmission.
18. Plug the transmission oil cooler pipe connectors in the transmission case.





19. Disconnect the wiring harness connectors from the transmission vehicle speed sensor and the park/neutral position switch.
20. Remove all vehicle harness wires, harness clips, tubes, brackets, and lines that may interfere with the removal of the transmission from the vehicle.





21. Remove the studs and the bolts securing the transmission to the engine.
22. Pull the transmission straight back.
23. Remove the transmission from the vehicle.
24. Inspect all the components for wear and damage.
25. Inspect all the seals and the fittings for signs of wear.
26. Inspect the torque converter for stripped or broken weld nuts.
27. Inspect the transmission case for cracks.
28. Perform the automatic transmission oil cooler flushing and flow test. Refer to Automatic Transmission Oil Cooler Flushing and Flow Test (J 45096) Automatic Transmission Oil Cooler Flushing and Flow Test (J 35944-A).

Installation Procedure
1. Support the transmission with a transmission jack.
2. Raise the transmission into place.
3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter.





Notice: Refer to Fastener Notice in Service Precautions.

Important:
^ The torque converter must be flush onto the flywheel and rotate freely by hand.
^ Do not install the transmission fluid fill tube.

4. Install the bolts that secure the transmission to the engine.
^ Tighten the studs and the bolts to 47 Nm (34 lb ft).





5. Install the bolts securing the torque converter to the engine flywheel.
1. First tighten all the bolts finger tight in order to insure proper converter seating.
2. Tighten the bolts to 63 Nm (46 lb ft).
6. If equipped with AWD, install the transfer case.





7. Install the wiring harness connectors to the vehicle speed sensor and the park neutral position switch.
8. Position and install all vehicle harness wires, harness clips, tubes, brackets, and lines that were removed or moved prior to the transmission removal.
9. Install the transmission fluid fill tube and the fill tube seal.
10. Install the transmission vent hose and the wiring harness to the transmission.





11. Install the sight shield.
12. Install the starter motor.
13. Install the exhaust pipe to the exhaust manifolds and the muffler assembly to the exhaust pipe.
14. Install the transmission support.
15. Remove the transmission jack and the engine support stands.
16. Install the rear propeller shaft.





17. Install the transmission range select cable to the transmission range select lever and the bracket.
18. Install the transmission oil cooler pipes.
19. Flush the transmission oil cooler and the pipes whenever you remove the transmission for overhaul, or replacement of the torque converter, the pump, or the transmission case.
20. Remove the safety stands.
21. Lower the vehicle.
22. Fill the transmission to the proper level using approved fluid.
23. Connect the battery negative cable assembly to the battery negative terminal.
^ Tighten the terminal bolt to 15 Nm (11 lb ft).