Repair Procedures
INSPECT TRANSMISSION FLUID AND DIAGNOSE GEAR SHIFT CONCERNSNOTE:
This bulletin does not apply if the transmission fluid is found to be 'burnt' as defined by the following conditions:
^ Badly 'burnt' transmission fluid will have a distinct smell, be black in coloration and may be contaminated with damaged friction linings.
^ Slightly 'discolored' transmission fluid is not necessarily 'burnt' fluid. Due to the transmission operating temperatures the fluid will, in most cases, appear slightly 'discolored'.
The procedures detailed in this bulletin are not suitable to repair transmissions diagnosed with gear flare/clutch pack failure or slipping bands.
1. Drain the transmission fluid completely and carefully inspect the fluid.
2. If the transmission fluid is not 'burnt' and is not contaminated with pieces of friction lining, diagnose which serviceable part(s) may be the cause for the gear shift concerns.
3. If the gear shift concerns are not a result of gear flare/clutch pack failure or slipping bands, refer to the applicable component replacement procedures that follow to replace the causal part(s) and repair the transmission.
REPLACE CONTROL VALVE BODY ASSEMBLY
CAUTION:
The gear selector lever must be in 'D1' drive position before removing the valve body securing bolts.
4. Move the gear selector lever to the 'D1' drive position.
5. Remove the three bolts securing the left-hand front splash shield and remove the shield.
6. Refer to the REMOVE FLUID PAN FOR ACCESS section and remove the fluid pan.
7. Disconnect the valve body electrical connectors. (Figure 1)
NOTE:
Only the silver colored bolts are removed to release the valve body.
8. Remove the eleven silver colored bolts securing the valve body to the transmission. (Figure 2)
9. Remove the valve body assembly.
10. Remove and discard both oil seals. (Figure 3)
11. Clean the new valve body assembly and mating faces.
CAUTION:
To avoid damage to the new oil seals, a smear of petroleum jelly must be applied. The oil seals must be correctly installed.
12. Lubricate the new oil seals (CAL500050 and CAL500060) and install into the sealing grooves in the automatic transmission. (Figure 3)
NOTE:
The transmission selector shaft plunger should protrude approximately 3 mm (1/8 in) from the valve body assembly, to help align the transmission selector shaft plunger to the transmission selector shaft pin.
13. Align the transmission shaft plunger to the selector shaft pin and install the new valve body assembly.
14. Tighten the eleven bolts to 8 Nm (6 lbf-ft). (Figure 2)
15. Manually operate the transmission gear selector in both directions to ensure the transmission selector shaft plunger operates correctly.
CAUTION:
The wiring harness must not be trapped behind the connector bracket. The electrical connectors must be fully connected.
16. Visually inspect the wiring harness and ensure correct routing.
17. Connect the valve body electrical connectors. (Figure 1)
18. Refer to the INSTALL FLUID PAN section of this bulletin and install the fluid pan.
19. Install the left-hand front splash shield and secure with the three retaining bolts.
REPLACE SHIFT SOLENOID
1. Refer to the REPLACE VALVE BODY ASSEMBLY section of this bulletin and complete Steps 1-6 to remove the valve body assembly.
2. Disconnect the solenoid electrical connector. (Arrowed in Figure 4)
3. Undo the bolt. (Arrowed in Figure 5)
4. Remove the solenoid.
5. Remove and discard the sealing ring.
6. Install a new sealing ring.
7. Install the new solenoid and tighten the bolt to 8 Nm (6 lbf-ft). (Figure 5)
8. Connect the solenoid electrical connector. (Figure 4)
9. Refer to the REPLACE VALVE BODY ASSEMBLY section of this bulletin and complete Steps 8-16 to install the valve body assembly.
REMOVE FLUID PAN FOR ACCESS
1. Drain the transmission fluid.
2. Remove the three bolts securing the left-hand front splash shield and remove the shield. (Figure 6)
3. Remove the three bolts securing the fluid cooler and position the cooler aside. (Arrowed in Figure 7)
4. Remove the M8 bolt securing the fluid cooler bracket to the transmission. (Arrowed in Figure 8)
5. Remove the upper M12 bolt securing the fluid cooler bracket to the transmission. (Arrowed in Figure 9)
6. Loosen the lower M12 bolt securing the fluid cooler bracket to the transmission and position the bracket out of the way. (Arrowed in Figure 10)
7. Remove the wiring connectors from the clips attached to the fluid pan. (Arrowed in Figure 11)
8. Remove the two nuts and remove the wiring connector retaining bracket.
CAUTION:
When using a slider or similar tool to remove the oil pan, tool access must be from the corners. Failure to follow this instruction may damage the harness, rendering the transmission unserviceable.
9. Remove the twenty bolts securing the fluid pan to the transmission. (Figure 12)
10. Remove the fluid pan.
INSTALL THE FLUID PAN
1. Clean the fluid pan and the mating face on the transmission.
2. Apply a suitable liquid gasket to the contact faces of the fluid pan and the transmission.
3. Position the fluid pan for installation.
4. Install the twenty bolts and tighten each progressively to 7 Nm (5 lbf-ft). (Figure 12)
5. Install the wiring connector retaining bracket and tighten the two nuts.
6. Secure the connectors to the clips. (Figure 11)
7. Position the fluid cooler bracket.
8. Tighten the lower M12 bolt to 85 Nm (62.5 lbf-ft). (Figure 10)
9. Tighten the upper M12 bolt to 85 Nm (62.5 lbf-ft). (Figure 9)
10. Tighten the M8 bolt to 25 Nm (18.5 lbf-ft). (Figure 8)
11. Position the fluid cooler and tighten the three bolts to 25 Nm. (18.5 lbf-ft). (Figure 7)
12. Install the left-hand front splash shield and secure with the three bolts. (Figure 6)
CAUTION:
Texaco N402 (LRN402) transmission fluid must be used. Transmission fluids other than that specified may result in serious damage to the transmission. For additional information, refer to TIB 10/01/05/NAS.
13. Fill the transmission with Texaco N402 (LRN402) transmission fluid.