SECTION 7C - AUTOMATIC TRANSMISSION (4L30-E)

Service Precaution

Construction

Range Reference Chart

Normal Operation of 2001 4L30–E

Transmission

Diagnosis

Driver Information

General Diagnosis Procedure

Preliminary Inspection Chart

Checking Transmission Fluid Level and

Condition

Test Driving

Mechanical / Hydraulic Diagnosis Check

Trans Indicator Chart

Mechanical / Hydraulic Diagnosis Symptoms

Index

Stall Test

Line Pressure Test

Shift Speed Chart

Lockup Speed Chart

Changing Transmission Fluid

Selector Lever

Inspection

Removal

Installation

Select Cable

Removal

Installation

Shift Lock Cable

Removal

Installation

Mode Switch

Removal

Installation

Transmission (With Transfer Case)

Transmission and Associated Parts

Removal

Installation

Solenoid (Main Case Valve Body)

Removal

Installation

Solenoid (Adapter Case Valve Body)

Removal

Installation

Valve Body Assembly (Main Case)

Removal

Installation

Valve Body Assembly (Adapter Case)

Removal

Installation

Powertrain Control Module (PCM)

Removal

Installation

Speed Sensor (Extension Housing)

Removal

Installation

Transmission Oil Temperature Sensor

(Main Case)

Removal

Installation

Front Oil Seal (Converter Housing)

Removal

Installation

Rear Oil Seal (Extension Housing)

Removal

Installation

Transmission (4L30–E)

Disassembly

Reassembly

Converter Housing and Oil Pump Assembly

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Oil Pump

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Main Case Valve Body

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Adapter Case Valve Body

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Third Clutch and Sprag Unit

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Third Clutch

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Sprag Unit

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Second Clutch

Disassembled View

Disassembly

Inspection and Repair

Reassembly

3–4 Accumulator Piston

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Reverse Clutch Piston and Center Support

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Overrun Clutch and Turbine Shaft

Disassembled View

Disassembly

Inspection and Repair

Reassembly

Main Data and Specification

Special Tools

4L30–E Parts List

SERVICE PRECAUTION

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS), REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING

SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING

SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE

INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT,

PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the

exact part number for that application. HOLDE N will call out those fasteners that require a repla cement after

removal. HOLDEN will also call out the fasteners that require thread lockers or thread sealant. UNLESS

OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)

on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener

torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the

correct tightening sequence and specifications. Following these instructions can help you avoid damage to

parts and systems.

CONSTRUCTION

A07RS001

EndOFCallout

Legend

(1) Torque Converter Clutch (TCC)

(2) Fourth Clutch (C4)

(3) Overrun Clutch (OC)

(4) Overdrive Unit

(5) Reverse Clutch (RC)

(6) Second Clutch (C2)

(7) Third Clutch (C3)

(8) Ravigneaux Planetary Gear Set

(9) Brake Band (B)

(10) Overdrive Free Wheel (One Way Clutch)

(OFW)

(11) Principle Sprag Assem bly (One Way Clutch)

(PFW)

RANGE REFERENCE CHART

C07RT010

NORMAL OPERATION OF 2001 4L30-E TRANSMISSION

4L30–E Transmission - Revised Operating Modes for MY2001

Torque Converter Clutch (TCC) Application Conditions:

Normal Mode:

The TCC is normally applied in 2nd, 3rd and 4th gears only when all of the following conditions exist:

– The engine coolant temperature is above 70°C .

– The brake pedal is released.

– The shift pattern requests TCC apply.

Hot Mode:

TCC is applied in 2nd, 3rd and 4th gears when the transmission oil temperature is above 135°C.

This mode should be canceled when transmission oil temperature falls below 125°C.

ATF Warning Lamp

The ATF warning lamp will be constantly on (not flashing) if the transmission oil temperature is above 145°C .

The ATF warning lamp goes off when the transmission oil temperature is below 125°C.

Reverse Lock Out

With the selector lever in reverse position, the PCM will not close the PWM solenoid until the vehicle is below 15 km/h,

thus preventing reverse engagement above this speed.

DIAGNOSIS

Introduction

The systematic troubleshooting information covered by this Section offers a practical and systematic approach to

diagnosing 4L30–E transmission, using information that can be obtained from road tests, electrical diagnosis, oil

pressure checks or noise evaluation.

The key to correcting a complaint is to make use of all of the available symptoms and logically letting them direct you

to the cause.

When dealing with automatic transmission complaints, it is best to gather as many symptoms as possible before

making the decision to remove the transmission from the vehicle.

Frequently, the correction of the complaint does not require removal of the transmission from the vehicle.

DRIVER INFORMATION

To analyse the problem fill out a complete description of the owner's complaint.

Please draw a circle aroun d the right i nforma tion and complete th e follo wing for m. (The ne xt page is an ex ample of a

completed form.) You can draw a circle around many numbers if you are not sure.

F07RT036

Example of a completed form.

F07RT037

GENERAL DIAGNOSIS PROCEDURE

F07RT038

PRELIMINARY INSPECTION CHART

F07R100002

CHECKING TRANSMISSION FLUID

LEVEL AND CONDITION

Checking fluid level and condition (color and odor) at

regular intervals will provide early diagnosis

information about the transmission. This information

may be used to correct a condition that, if not detected

early, could result in major transmission repairs.

Important: When new, automatic transmission fluid is

red in color. As the vehicle is driven, the transmission

fluid will begin to look darker in color. The color may

eventually appear light brown.

A dark brown color with burnt odor may indicate

excessive fluid deterioration and signal a need for fluid

change.

Fluid Level

When adding or changing fluid, use only

DEXRON ®–III.

Refer to Section 0B Maintenance and Lubrication for

maintenance information and servicing interval.

CAUTION: DO NOT OVERFILL.

Overfilling will cause foaming, loss of fluid,

abnormal shifting and possible damage to the

transmission.

NOTE: The transmission fluid temperature must be

less than 30°C (Check with Tech 2 scan tool) before

proceeding with the level check.

1. Park the vehicle on level ground and apply the

parking brake firmly.

2. Move the selector lever through all gear ranges.

3. Move the selector lever to “Park".

4. Let engine idle for 3 minutes and open the overfill

screw (1).

5. Add clean transmission fluid until it flows out of the

overfill screw opening.

6. Let engine idle until a fluid temperature between

32°C and 57°C is reached, then refit the overfill

screw (1).

Torque: 38Nm

NOTE: To prevent fluid leaks, the overfill screw and oil

drain screws gaskets must be replaced each time these

screws are removed.

Minimum fluid level → 57°C

Maximum fluid level → 32°C

242R200001

CAUTION: Do not open overfill screw with engine

stopped.

CAUTION: DO NOT CHECK FLUID LEVEL UNDER

THESE CONDITIONS:

• Immediately after driving at sustained highway

speeds.

• In heavy city traffic during hot weather.

• If vehicle is towing a trailer.

If the vehicle has been operated under these conditions,

shut the engine off and allow the vehicle to “cool" for

thirty (30) minutes. After the cool down period, restart

the vehicle and continue from step 2 above.

Fluid Condition

*Fluid should be changed according to maintenance schedule. Refer to Section 0B

TEST DRIVING

Some 4L30–E automatic transmission complaints will

require a test drive as a part of the diagnostic

procedure. Some codes will not set unless the vehicle is

moving. The purpose of the test drive is to duplicate the

customer's complaint condition and set a current

Powertrain Control Module (PCM) DTC. Perform this

procedure before each 4L30–E automatic transmission

repair, and again after repairs are made.

Important:

• Duplicate the condition under which the customer's

complaint was observed.

• Depending on the complaint, the line pressure gauge

and the scan tool may be required during the test

drive.

• During the test drive, it is important to record all

necessary data from the areas being monitored, for

use in diagnosis. Also listen for and note any

unusual noises.

The following procedure should be used to test drive

4L30–E automatic transmission complaint vehicles:

1. Turn the ignition ON without starting the engine.

Check that the “CHECK TRANS" lamp comes on for

approximately 2 seconds and then goes out and

remains out.

• If the lamp is flashing, GO TO Check Trans

Indicator in Transmission Control System (4L30–

E) section.

• If no serial data is present, GO TO OBD System

Check. Refer to Driveability and Emissions in

Engine section.

• If the lamp stays ON or stays OFF, GO TO

“Check Trans" Check in Transmission Control

System (4 L30 –E) sec ti on.

2. Drive the vehicle. During the test drive, be sure that

the transmission achieves normal operating

temperature (approx. 20 minutes).

Allow the transmission to go through all of its gear

ranges, checking shift timing and firmness.

Duplicate the owner's complaint condition as

closely as possible during the test drive.

3. If, during the test drive, the “CHECK TRANS" lamp

comes on, use the scan tool to check for trouble

codes.

4. If, during the test drive, a problem is felt, but the

“CHECK TRANS" lamp does not come on and no

troubl e cod es ar e pres en t, d riv e th e ve hic le with the

PCM disconnected (manually shifting the vehicle).

• In Manual L, the vehicle operates in first gear.

• In Manual 2, the vehicle operates in third gear.

• I n Manual 3 or “D", the vehicl e operates in fourth

gear.

FLUID CONDITION

NORMAL* CONTAMINATED

COLOR RED OR LIGHT

BROWN BROWN NON–TRANSPARENT

/ PINK BROWN

Drain

Required? NO YES YES YES

Contamination NONE Very small amount of

foreign material in

bottom of pan

Contamination by

coolant or other source Large pieces of metal

or other foreign

material in bottom of

pan

Correct Level

And Condition 1. LOW LEVEL:

– Add fluid to

obtain proper

level & check for

external leaks.

– Correct cause of

leak.

2. HIGH LEVEL:

– Remove excess

fluid

– Remove both pans

– Change filter

– Flush cooler

– Add new fluid

– Check level

– Repair/replace

radiator cooler

– T r ansmission

overhaul required

– Check for:

• D ama ged pla tes

and seals

• Contaminated

solenoids

– Flush cooler

– Add new fluid

–Check level

– Transmission

overhaul required

– Flush cooler and

cooler lines

– Add new fluid

– Check level

If the problem still exists with the PCM

disconnected, refer to Mechanical/Hydraulic

Diagnosis in this section.

5. I f no probl em has b een fou nd at this poi nt, ch ec k all

underhood connections that supply power to the

PCM and ignition fuses. Physically and visually

inspec t a ll t he P CM ha r nes s con nec tor s for lo os e or

corroded terminals. Inspect the PCM ground points.

MECHANICAL / HYDRAULIC DIAGNOSIS CHECK TRANS INDICATOR CHART

Perform Preliminary Inspection First!

When the “CHECK TRANS" indicator is flashing, it indicates that a problem related to the transmission, the

Powertrain Control Module (PCM), or the vehicle harness has occurred.

The s ystem i s n ow ope ra tin g in a “ BACK U P MODE" where the r isk of fur th er d ama gin g the tr a ns miss ion h as b een

reduced. The vehicle may be shifted manually.

If the initial problem is intermittent or seldom, switching the engine OFF/ON might allow normal operation again until

the problem reoc cu rs.

F07RT013

MECHANICAL / HYDRAULIC DIAGNOSIS SYMPTOMS INDEX

Perform Preliminary Inspection First!

NOTE: Numbers with parenthesis on the following charts refer to those on Parts List at end of this section.

Chart 1: No Engine Start In Neutral Or Park

CHART SYMPTOMS

1 NO ENGINE START IN NEUTRAL OR PARK

2 NO FORWARD GEARS IN ANY RANGE/NO REVERSE

3 NO ENGINE BRAKE IN ANY RANGE

4 POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)

5a DELAYS IN DRIVE AND REVERSE

5b DELAYS IN REVERSE ONLY

6 DIAGNOSTIC TROUBLE CODE (DTC) P0730

7 HARSH 1–2 SHIFT

8 HARSH 3–4 SHIFT

9a 3–2 DOWNSHIFT COMPLAINT

9b HARSH SHIFT WHEN SHIFTING INTO “D" OR ACCELERATING FROM STOP

9c COASTDOWN HARSH SHIFT OR CLUNK AT 3–2 DOWNSHIFT

10 INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED

11 ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE)

12 ENGINE FLARE DURING 1–2 OR 2–3 SHIFT

13 SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING

14 POSSIBLE CAUSES OF TRANSMISSI ON NOISE

15a POSSIBLE CAUSES OF LOW LINE PRESSURE

15b POSSIBLE CAUSES OF HIGH LINE PRESSURE

16 POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS

Step Action Yes No

1 Does engine start when shift lever moved from drive to neutral

mostly in hot condition? Go to Step 2 Go to Step 3

2 Does engine start in park at any condition? Re–test vehicle Go to Step 4

3 Does engine also not start in neutral when shift lever moved from

park to neutral? Go to Step 4 Go to Step 5

4 Check mode switch (63) setting. Readjust if necessary.

Problems fixed? Re–test vehicle Go to Step 5

5 Check start circuit of mode switch (63) open in neutral.

Was open found? Locate and repair

open(s). Replace mode

switch (63).

Chart 2: No Forward Gears In Any Range/No Reverse

Chart 3: No Engine Brake In Any Ra nge

Step Action Yes No

1 Check line pressure. Refer to Li ne Pr essure Tes t in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15a:

“Possible Causes of

Low Line Pressure”

in this section.

2 1. Check internal li nkage:

– Manual linkage (58) not moving manual valve (326).

2. Check for internal mechanical damage:

– Turbine shaft (506) broken loose.

– Overrun roller clutch (516) broken loose.

Was the problem found? Repair or replace —

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15a:

“Possible Causes of

Low Line Pressure”

in this section.

2 1. Check for overrun clutch leaks caused by:

– Damaged piston lip (513)

– Check ball defective (504)

2. Check for overrun lockout valve (705) stuck by foreign

material.

3. Check for leaks at turbine shaft (506) caused by:

– Teflon seal rings damaged (508)

– Excessive wear of turbine shaft bearing surfaces.

Was the problem found? Repair or replace —

Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft)

Chart 5a: Delays In Drive and Reverse

NOTE: A sh or t delay (les s th an 3 s ec on ds ) when fi rst en gag ing drive or reverse after al low ing ve hic le to s it ov erni gh t

is normal.

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal? Go to Step 2 Go to Step 3

2 1. Check for these conditions which could affect clutch apply

time:

– Defective band apply solenoid (323).

– Defective servo or/and accumulator piston.

– Excessive clut ch piston travel.

2. Check of possible causes of internal leaks:

– Cut or damaged sealing ring(s)

– Damaged sea li ng gas ke t(s)

– Check ball mi ssing or out of location in 2nd and 3rd clutch

pistons.

3. Check for causes of burned clutch plates or band.

Was the problem found? Repair or replace —

3 Was the line pressur e high?

Go to Step 4

Use Chart 15b:

“Possible Causes of

High Lin e Pre s sure”

in this section.

4 Were DTC P0705 set?

Diagnose those

DTC(s) first.

Use Chart 15b:

“Possible Causes of

High Lin e Pre s sure”

in this section.

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal? More than 3

second delay in

drive and

reverse with

engine off 1

hour or less.

Teflon seals

(508) on turbine

shaft damaged.

Repair

Use Chart 15a:

“Possible Causes of

Low Line Pressure”

in this section.

Chart 5b: Delays In Reverse Only

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15a:

“Possible Causes of

Low Line Pressure”

in this section.

2 Main case valve body gasket (88) damaged.

– Reverse check ball (85) in valve body (84) missing or out of

location.

– Check for restrictions at valve body transfer plate orifice.

Was the problem found? Repair —

Chart 6: Diagnostic Trouble Code (DTC) P0730

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15b:

“Possible Causes of

High Lin e Pre s sure”

in this section.

2 1. 1st and 2nd gear missing or 3rd and 4th gear missing.

Check appropriate shift valve. If OK replace solenoid.

2. No engine brake in any range (All ranges in Drive and

Reverse are OK)

Check for suspected conditions modifying delays to clutch

apply:

– Overrun clutch seal damaged.

– Excessive overrun clutch piston travel.

– Defective 3-4 accumulator piston.

– Causes of internal leaks.

– Causes of burned clutch plates.

3. 1st and 4th gear missing or 2nd and 3rd gear missing.

Shift solenoid A stuck. Replace shift solenoid A.

4. DTC P0730 is set in D range 1st gear above 3500 rpm.

Go to Step 3.

5. DTC P0730 is set in D range 3rd gear between 55-80 mph.

NOTE: Perform this test within safe and legal limits.

Check for suspected conditions modifying delays to clutch

apply:

– 4th clutch seal damaged.

– Excessive 4th clut ch piston travel.

– Defective 3-4 accumulator piston.

– Causes of internal leaks.

– Causes of burned clutch plates.

Was the problem found? Repair or replace —

3 Check 3rd gear in “D" in winter mode.

Does ve hicl e move? Shift solenoid ‘A’

stuck. Replace

shift solenoid ‘A’. Go to Step 4

4 Check for suspected conditions modifying delays to clutch apply:

– 2nd clutch seal damaged.

– Excessive 2nd clutch piston travel.

– Defective accumulator piston.

– Causes of internal leaks.

– Check ball missing or out of location in 2nd clutch.

– Seals cut, damaged or missing.

– Gaskets defective.

– Causes of burned clutch plates.

Was the problem found? Repair or replace —

Chart 7: Harsh 1–2 Shift

Chart 8: Harsh 3–4 Shift

Chart 9a: 3–2 Downshift Complaint

Chart 9b: Harsh Shift When Shifting Into “D" Or Accelerating From Stop

Chart 9c: Coastdown Harsh Shift Or Clunk At 3–2 Downshift

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal? Check for 1–2

accumulator valve

(320) stuck by

foreign material in

main case valve

body.

Use Chart 15b:

“Possible Causes of

High Lin e Pre s sure”

in this section.

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15b:

“Possible Causes of

High Lin e Pre s sure”

in this section.

2 1. Check for 3–4 acc umu lat or va lv e (4 0 7) stuck in ada pte r ca se

valve body (401).

2. Che ck for 3–4 a ccumula tor piston ( 18) stu ck in adapter case

(20).

Was the problem found? Repair or replace —

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15a:

“Possible Causes of

Low Line Pressure”

in this section.

2 Does DTC P1850 set? Diagnose P1850

first.

Replace ban d

apply solenoid

(PWM) (323).

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15b:

“Possible Causes of

High Lin e Pre s sure”

in this section.

2 Does DTC P1850 set? Diagnose P1850

first.

Replace ban d

apply solenoid

(PWM) (323).

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15b:

Possible Causes of

High Line Pressure

in this section.

2 Does DTC P1850 set? Diagnose P1850

first.

Replace ban d

apply solenoid

(PWM) (323).

Chart 10: Intermittent 4TH TO 2ND Gear Downshift At Steady Speed

Chart 11: Engine Flare At Shifting During Turning Only (Usually With Warm Engine)

Chart 12: Engine Flare During 1–2 Or 2–3 Shift

Step Action Yes No

1 Check for consistent speed sensor reading with scan tool.

Was the reading correct? Replace mod e

switch f or

intermittent

contact. Go to Step 2

2 1. Check for wiring harness damage or short to ground. If OK,

go to (2).

2. Check transmission speed sensor connections. If OK, go to

(3).

3. Replace transmission speed sensor.

Was the replacement complete? — Replace speed

sensor.

Step Action Yes No

1 Check for oil leaks at transmission.

Was the problem found? Replace

transmission oil

filter and gasket. —

Step Action Yes No

1 Check line pressure. Refer to Line Pressure Test in this section.

W as line pressure normal?

Go to Step 2

Use Chart 15a:

“Possible Causes of

Low Line Pressure”

in this section.

2 1. Check for a stuck 1–2 accumulator valve (320).

2. Check for servo piston (106) leaks.

3. Check for a stuck band apply solenoid (323).

Was line pressure normal? Repair or replace —

Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying

Chart 14: Possible Causes of Transmission Noise

CAUTION: Before checking transmission for what is believed to be transmission noise, ensure presence

and positioning of insulating plugs, pads etc. Also make sure that noise does not come from other

drivetrain comp onents.

Step Action Yes No

1 1. TCC shudder is one of the most commonly misdiagnosed

conditions in an automatic transmission. The key to

diagnosing TCC shudder is to note when it happens and

under wha t co ndi tio ns . O nc e the TCC ha s been full y appl ie d,

it is nearly impossible to make it shudder. TCC shudder

(short burst of noise normally less than 1 second) will only

occur during clutch applying. It is not a steady state condition.

2. Drive until whole drivetrain is at normal operating

temperature.

– On 4WD vehicles, the test must be performed with transfer

case selector lever in “2H" position.

– Shudder is a short burst of noise normally less than 1

second in duration, and can be induced by the following

maneuver:

3. F rom co ast conditi on at 80km/h in “D " rang e (No rmal mo de),

depress the throt tle to 1/4 -1 /3 thr ott le. If pres ent , shud der will

occur within 5 second s toge the r with TCC appli catio n. (The

scan tool may be used to determine the exact time of TCC

application).

Was the problem found?

Replace

transmission fluid

and filter (remove

both pans) and flush

cooler lines.

Go to Step 2

Perform mechanical

inspection of other

drivetrain

components -

Repair/replace as

required.

Verify Repair

2 Does the pr obl em still exis t? Go to Step 3 -

3 Replace converter assembly and O-ring on turbine shaft Verify repair -

Condition Possible cause Correcti on

Whine or Buzz Oil level low Fill with ATF, check for external

leaks.

Plugged or restricted oil filter Inspect oil filter.

Replace oil filter or ATF as

necessary.

Damaged oil filter gasket Replace oil filter gasket.

Knocking noise from front of

transmission. Loose bolts (Converter to flex plate) Tighten to specifications.

Cracked or broken flex plate Replace flex plate.

Converter damaged Replace converter.

Knock ing no ise whil e drivi ng, mos tly

on acceleration. Transmission mount loose or broken Tighten mount bolts or replace

transmission mount.

Cooler line mounts loose or broken Tighten or replace cooler line

mounts.

Cooler lines touching body or frame Repair or replace as necessary.

Knocking noise when vehicle is

stationary. Loose flex plate mounting bolts Tighten to specifications.

Cracked or broken flex plate Replace flex plate.

Damaged conver ter Replac e conv erter.

Chart 15a: Possible Causes of Low Line Pressure

Step Action Yes No

1 Check oil level.

Was the problem found? Fill with ATF. Go to Step 2

2 Check for defective throttle position sensor.

Was the problem found? Replace throttle

position sensor. Go to Step 3

3 Check for plugged, loose, or damaged oil filter (79).

Was the problem found? Inspect oil filter,

tighten bolts or

replace oil filte r

(79). G o to Step 4

4 Check for a stuck Pressure Control Solenoid plunger (404).

(Adapter case valve body)

Was the problem found?

Replace Pressure

Control Solenoid

plunger (404). Go to Step 5

5 Check for a stuck feed limit valve (412). (Adapter case valve

body)

Was the problem found? Replace feed limit

valve (412). Go to Step 6

6 Check for loose converter bolts (4 & 5).

Was the problem found? Tighten converter

bolts (4 & 5). Go to Step 7

7 Check for a stuck pressure regulator valve (208). (Oil pump)

Was the problem found? Replace pressure

regulator valve

(208). Go to Step 8

8 Check for a stuck boost valve (205). (Oil pump)

Was the problem found? Replace boost

valve (205). Go to Step 9

9 Check for blocked intermediate oil passages to pressure

regulator valve. (Oil pump)

Was the problem found? Replace oil pump. Go to Step 10

10 Check for defective oil pump (9, 201, 202 & 209).

Was the problem found? Replace oil pump. Go to Step 11

11 Check for internal leaks.

– Check balls missing or out of location in valve bodies

– Seals cut or damaged

– Gaskets defective, etc.

Was the problem found?

Install balls, or

correct ball

location.

Replace seals.

Replace

gaskets. —

Chart 15b: Possible Causes of High Line Pressure

NOTE: If transmission is operating in backup mode, high line pressure will be present.

Chart 16: Possible Causes of Transmission Fluid Leaks

Before atte mpting to corr ect an oil l eak, the actual sou rce of th e leak must be dete rmined. In many ca ses, th e so urce

of the leak may be difficult to determine due to “wind flow" around the engine and transmission.

The suspected area should be wiped clean before inspecting for the source of the leak.

Oil lea ks arou nd th e en gine and tr an sm is si on are ge ner al ly car ried towar d the r ea r o f the ve hi cl e by th e ai r s tream. In

determining the source of an oil leak, the following two checks should be made:

1. With the engine running, check for external line pressure leaks.

2. With the engine off, check for oil leaks due to the raised oil level caused by drainback of converter oil into the

transmission.

Step Action Yes No

1 Check for defective throttle position sensor.

Was the problem found? Replace throttle

position sensor. Go to Step 2

2 Check for a stuck Pressure Control Solenoid plunger (404).

(Open circuit/intermittent) (Adapter case valve body)

Was the problem found?

Replace Pressure

Control Solenoid

plunger (404). Go to Step 3

3 Check for a stuck feed limit valve (412). (Adapter case valve

body)

Was the problem found? Replace feed limit

valve (412). Go to Step 4

4 Check converter bolts (4 & 5).

Was the problem found? Tighten converter

bolts (4 & 5). Go to Step 5

5 Check for a stuck pressure regulator valve (208). (Oil pump)

Was the problem found? Replace pressure

regulator valve

(208). Go to Step 6

6 Check for a stuck boost valve (205). (Oil pump)

Was the problem found? Replace boost

valve (205). Go to Step 7

7 Check for internal leaks.

– Check balls missing or out of location in valve bodies

– Seals cut or missing

– Gaskets defective, etc.

Was the problem found?

Install balls, or

correct ball

location.

Replace seals.

Replace

gaskets. —

Possible Causes of Fluid Leaks Due To Sealing Malfunction

240RX008

EndOFCallout

STALL TEST

The stall test allows you to check the transmission for internal abrasion a nd the one way clutch for slippage. Torque

converter performance can also be evaluated.

The stall test results together with the road test results will identify transmission components requiring servicing or

adjustment.

Stall Test Procedure:

1. Check the level of the engine coolant, the engine oil, and the automatic transmission fluid. Replenish if necessary.

2. Block the wheels and set the parking brake.

3. Connect a tachometer to the engine.

4. Start the engine and allow it to idle until the engine coolant temperature reaches 70 – 80°C (158 – 176°F).

5. Hold the brake pedal down as far as it will go.

6. Place the selector in the “D" range.

Legend

(1) Electrical Connector (Main Case) Seal

(2) Transmission Vent (Breather)

(3) Speed Sensor O–ring

(4) Extension (Adapter) Lip Seal

(5) Extension (Adapter) to Main Case Gasket

(6) Overfill and Oil Drain Screws Gasket

(7) Oil Pan Gasket (Main Case)

(8) Selector Shaft Seal

(9) Oil Cooler Connectors (2)

(10) Oil Pan Gasket (Adapter Case)

(11) Converter housing attaching bolts not correctly

torqued

(12) Converter Housing Lip Seal

(13) Line Pressure Tap Plug

(14) Electrical Connector (Adapter Case) Seal

(15) Adapter Case Seal Rings (2)

7. Gradually push the accelerator pedal to the floor.

The throttle valve will be fully open.

Note the engine speed at which the tachometer needle stabilizes.

Stall Speed : 2,100 ±150 rpm

NOTE: Do not continuously run this test longer than 5 seconds.

8. Release the accelerator pedal.

9. Place the selector in the “N" range.

10. Run the engine at 1,200 rpm for one minute.

This will cool the transmission fluid.

11. Repeat Steps 7 – 10 for the “3", “2", “L" and “R" ranges.

LINE PRESSURE TEST

The line pressure test checks oil pump and control valve pressure regulator valve function. It will also detect oil

leakage.

Line Pressure Test Procedure:

1. Check the level of the engine coolant, the engine oil,

and the automatic transmission fluid.

Replenish if required.

2. Block the wheels and set the parking brake.

3. R emove the pressure detection plug at the lef t side

of the transmission case.

Set J–29770–A pressure gauge and adapter to the

pressure test point.

4. Start the engine and allow it to idle until the engine

cool ant temperature reaches 70 – 80°C

5. Hold the brake pedal down as far as it will go.

6. Place the selector in the “D" range.

7. Note the pressure gauge reading with the engine

idling.

8. Gradually push the accelerator pedal to the floor.

The throttle valve will be fully open.

Note the pressure gauge reading with the

accel er ato r peda l full y depress ed .

NOTE: Do not continuously run this test longer than 5

seconds.

9. Release the accelerator pedal.

10. Place the selector in the “N" range.

11. Run the engine at 1,200 rpm for one minute.

This will cool the transmission fluid.

12. Repeat Steps 7 – 11 for the “3", “2", “L", and “R"

ranges.

13. I nstall a pre ssure dete ction plug to th e tra nsmiss ion

case, applying recommended thread locking agent

(LOCTITE 242) or its equivalent to thread of plug.

Make sure that thread is cleaned before applying

locking agents.

14. Tighten the pr essure detecti on plug to the s pecified

torque.

Torque:9–14Nm

MODE LEVER

POSITION E NG INE SP EE D

LINE PRESSURE PRESSURE

CONTROL

SOLENOID

CURRENT (mA)

kPa PSI

NORMAL/POWER D,3,2,L IDLE 590–730 86–106 680–720

WINTER D IDLE 300–390 44–57 1,020–1,060

NORMAL/POWER

WINTER REVERSE IDLE 460–630 67–91 880–920

NORMAL/POWER D, 3, 2, L STALL SPEED 1,250–1,380 181–200 70–110

WINTER D STALL SPEED 1,250–1,380 181–200 70–110

NORMAL/POWER

WINTER REVERSE STALL SPEED 1,400–1,580 203–229 340–380

SHIFT SPEED CHART

“Normal mode"

Upshift

Downshift

“Power mode"

Upshift

Downshift

“Winter mode"

Transfer gear ratio High: 1.000

Rear axle ratio 4.100

Range Throttle

opening

1 → 2

(First Gear) (Second

Gear)

km/h

2 → 3

(Second Gear) (Third

Gear)

km/h

3 → 4

(Third Gear) (Fourth

Gear)

km/h

(Drive) Fully opened 54 ∼ 60 111 ∼ 117 169 ∼ 175

Half throttle 34 ∼ 40 64 ∼ 70 117 ∼ 123

Range Throttle

opening

1 ← 2

(First Gear) (Second

Gear)

km/h (mph)

2 ← 3

(Second Gear) (Third

Gear)

km/h (mph)

3 ← 4

(Third Gear) (Fourth

Gear)

km/h (mph)

(Drive)

Fully opened 46 ∼ 52 89 ∼ 95 159 ∼ 165

Half throttle 15 ∼ 21 36 ∼ 42 74 ∼ 80

Fully closed 14 ∼ 20 21 ∼ 27 28 ∼ 34

Range Throttle

opening

1 → 2

(First Gear) (Second

Gear)

km/h

2 → 3

(Second Gear) (Third

Gear)

km/h

3 → 4

(Third Gear) (Fourth

Gear)

km/h

(Drive) Fully opened 54 ∼ 60 111 ∼ 117 169 ∼ 175

Half throttle 42 ∼ 48 78 ∼ 84 133 ∼ 139

Range Throttle

opening

1 ← 2

(First Gear) (Second

Gear)

km/h

2 ← 3

(Second Gear) (Third

Gear)

km/h

3 ← 4

(Third Gear) (Fourth

Gear)

km/h

(Drive)

Fully opened 46 ∼ 52 89 ∼ 95 159 ∼ 165

Half throttle 23 ∼ 29 59 ∼ 65 108 ∼ 114

Fully closed 14 ∼ 20 24 ∼ 30 48 ∼ 54

D range, winter mode ON → OFF 31 ∼ 37 km/h

LOCKUP SPEED CHART

Transfer gear ratio High: 1.000

Rear axle ratio 4.100

D range, Throttle

opening 6%

Mode Lockup ON Lockup OFF

2nd

km/h 3rd

km/h 4th

km/h 2nd

km/h 3rd

km/h 4th

km/h

Normal 75 ∼ 81 68 ∼ 74 76 ∼ 82 69 ∼ 75 47 ∼ 53 72 ∼ 78

Power 75 ∼ 81 80 ∼ 86 80 ∼ 86 69 ∼ 75 7 1 ∼ 77 75 ∼ 81

CHANGING TRANSMISSION FLUID

There is no need to change the transmission fluid

unless the transmission is used under one or more of

the following heavy duty conditions.

A Repeated short trips

B Driving on rough roads

C Driving on dusty roads

D Towing a trailer

If the vehicle is used under these conditions, change the

fluid every 20,000 miles (32,000 km.)

More over, the remaining life percentage of ATF can be

estimated by using Tech 2 as an auxiliary tool to judge

the right time for ATF replacement.

The remaining life percentage is calculated from ATF'S

heat history. When it is close to 0%, ATF replacement is

recommended.

1. Place a large drain pan under the oil pan.

2. Remove the transmission oil drain screw (2) and

drain fluid.

3. Tighten drain screw (2).

Torque: 38N•m

4. Remove the transmission overfill screw (1) and fill

transmission through overfill screw opening, using

DEXRON®-III ATF.

NOTE: Add transmission fluid until it flows out over the

overfill screw opening.

5. Let engine idle until a fluid temperature between

32°C and 57°C is reached.

6. Add transmission fluid until it flows out over the

overfill screw opening, then close the overfill screw

(1).

Torque: 38N•m

NOTE: To prevent fluid leaks, the overfill screw and oil

drain screws gasket must be replaced each time these

screws are removed.

NOTE: Check transmission fluid temperature with scan

tool.

7. Reset “Oil Life Monitor" data by using Tech 2.

Refer to Tech 2 Connection in section 0C.

242R200001

SELECTOR LEVER

INSPECTION

1. Make sure that when the selector lever is shifted

from “P" to “L", a “clicking" can be felt at each shift

position. Make sure that the gear corresponds to

that of the position plate indicator.

2. C heck to see if the selector lever can be shifted as

shown in illustrat ion.

C07RW009

REMOVAL

1. Disconnect battery ground cable.

2. Set ignition Key in “LOCK" position and selector

lever in "P" position.

3. Remove transfer control lever knob.

4. Remove lower cluster assembly.

740RW021

5. Remove rear console.

745RW011

6. Remove center console

256RW006

7. Remove selector lever knob and cover.

256RW043

8. Disconnect select cable.

•Refer to Select Cable in this section.

9. Disconnect shift lock cable.

•Refer to Shift Lock Cable in this section.

10. Disconnect harness connector.

11. Remove selector lever subassembly.

256RW044

INSTALLATION

1. Install selector lever subassembly.

2. Connect harness connector.

3. Connect shift lock cable.

• Refer to Shift Lock Cable in this section.

4. Connect select cable.

• Refer to Select Cable in this section.

5. Install selector lever knob and cover.

256RW043

6. Install center console.

7. Install rear console.

8. Install lower cluster assembly.

9. Install transfer control lever knob.

10. Connect negative (–) battery cable.

11. After installation, make sure that the selector lever

operates normally, and that each selector position

is properly indicated. (The red mark shows through

the window.)

SELECT CABLE

REMOVAL

1. Set selector lever in “P" position.

2. Remove transfer control lever knob, lower cluster

assembly, rear console, center console, selector

lever knob and cover.

• Refer to Selector Lever in this section.

3. Disconnect inner cable by pulling projection on pin.

256RW022

4. Press down claws and disconnect cable assembly.

A07RW017

5. Disconnect PCM harness connectors and remove

nuts that fasten grommet in select cable assembly.

6. Disco nne ct inn er cabl e.

210RW013

7. Slide sleeve and disconnect cable assembly.

A07RW082

8. Pull lock.

A07RW015

9. Draw select cable assembly into the interior side.

INSTALLATION

1. Set selector lever in “P" position.

2. Let out select cable transmission side end from floor hole.

3. Fit outer cable into bracket in selector lever assembly.

A07RW016

4. Set inner cable end in selector lever and push pin into selector lever hole and inner cable end.

256RW023

5. Check that lock projects.

A07RW015

6. Connect adjust end fitting attachment to the bracket

on transmission.

7. Set selector lever “P" position and connect inner

cable to selector lever.

210RW013

8. Push lock into adjust end fitting attachment.

A07RW014

9. Install grommet.

10. About following installation steps, refer to Selector

Lever in this section.

SHIFT LOCK CABLE

REMOVAL

1. Set ignition key in “LOCK" position and selector

lever in “P" position.

2. Remove transfer control lever knob, lower cluster

assembly, rear console, center console, selector

lever knob and cover.

• Refer to Selector Lever in this section.

3. Disconnect inner cable from selector lever assembly

then push claw and disconnect cable assembly.

256RW016

4. Disconnect lock adjust.

256RW017

5. Remove instrument panel lower cover and steering

column cover.

6. Remove spring pin and disconnect inner cable.

• Disconnect outer cable from bracket.

256RW008

INSTALLATION

1. Set ignition key in “LOCK" position and selector

lever in “P" position.

2. Connect outer cable to bracket near steering lock.

• Connect inner cable to steering lock and install

spring pin .

3. Install steering column cover and instrument lower

cover.

4. Install adjust body of cable assembly to bracket in

selector lever assembly.

• Install inner cable to lever, pulling inner cable with

outer cable.

256RW018

5. Check that cable moves smoothly, lightly pulling

outer cable rearward.

256RW019

6. Connect lock adjust, aligning “T" mark in the “Up"

position.

256RW017

7. About following installation steps, refer to Selector

Lever in this section.

8. Check the shi ft lock opera tio n:

a Selector lever should not be moved out of “P"

position with ignition key in “Lock" position.

b Select or lever can be mo ved out of “P" position

with ignition key in “ON" position only when

brake pedal is depressed.

c ignition key can be turned to “LOCK" position

only when selector lever is in “P" position (key

can be pulled out).

9. If a. and c. fail, readjust cable. If b. fails, readjust

connector wiring and brake pedal switch.

MODE SWITCH

REMOVAL

1. Place selector lever in neutral.

2. Disconnect battery ground cable.

3. Remove mode switch cover (1).

4. Disconnect selector lever (2) from the mode switch.

5. Remove bracket with cable (3).

6. Disconnect transmission harness from the mode

switch connector (4).

7. Remove bracket with mode switch connector from

the transmission case.

8. Remove mode switch connector (4) from the

bracket (5).

9. Remove two mode switch bolts and nut then

remove mode switch (6).

210RW014

INSTALLATION

To install, follow the removal steps in the reverse order,

noting the following points;

1. Torque

Mode switch bolt: 13N•m

Selector lever nut: 23N•m

2. Mode switch setting procedure

Perform either of the following adjustment

procedures:

Procedure 1

a Place select or lever in neutral.

b Remove selector lever from the mode switch.

c Remove the mode switch cover.

d Loosen the two 10 mm screws.

e Rotate the mode switch until the slot in the

mode switch housing aligns with the selector

shaft bushing, and insert a 2.4 mm drill bit or

punch (1) into the slot.

f Tighten the screws to 13 N·m.

g After completing adjustment, snap the mode

switch cover into place.

h Reinstall the selector lever.

249RW001

Procedure 2

a Place selector lever in ne utral.

b Disconnect transmission harness connector

from mode switch connector.

c Remove mode switch connector with bracket

from the transmission case.

d Connect multimeter (resistance mode) to

terminals 1(E) and 4(H) on mode switch

connector.

e Loosen two mounting screws.

f Rotate mode s witch slight ly in both di rections to

determine the range (approx. 5 degrees) of

electrical contact.

g Position mode switch in middle of contact range.

h Tighten two mounting screws.

i Remove multimeter and install mode switch

harness connector with bracket to the

transmission case.

j Connect transmission harness connector to

mode switc h conn ector.

F07RW003

TRANSMISSION (WITH TRANSFER CASE)

TRANSMISSION AND ASSOCIATED

PARTS

240RX012

EndOFCallout

Legend

(1) Skid Plate

(2) Transfer Case Guard

(3) Rear Propeller Shaft

(4) Front Propeller Shaft

(5) Center Exhaust Pipe

(6) Harness Heat Shield

(7) Rear Mount Nut

(8) Third Crossmember

(9) Transmission Oil Cooler Pipe

(10) Starter

(11) Under Cove r

(12) Transfer Control Lever

(13) S elect Cable

(14) Torque Converter Bolt (Non – reusable part)

(15) Engine-Transmission Bolt

(16) Transmission Assembly (With Transfer Case)

REMOVAL

Before remove transmission and transfer assembly from

vehicle, change the transfer mode to 2WD using push

button on dash panel.

1. Disconnect battery ground cable.

2. Remove rear propeller shaft and front propeller

shaft.

NOTE: Apply alignment marks on the flange at both

front and rear sides.

401RW008

401RW007

3. Remove transfer protector.

4. Remove center exhaust pipe.

150RX008

5. Remove fuel pipe bracket from the third

crossmember.

141RX004

141RY00007

240RW014

Fuel hose connector removal procedure

If remov al of the fuel ho se connector i s required for

transmission servicing and/or replacement, follow

the steps below.

NOTE:

• An O-ring is used as a seal between the fuel pipe and

the connector. Take care not to damage the contact

surfaces during the removal pro cedure. Do not allow

the serfaces to become contaminated with dirt or

other foreign material.

• Perform the entire removal procedure with your

hands. Do not use tools.

1. Separating the connector and fuel pipe

1. Clean the fuel pipe and connector to remove

mud and other dirt.

2. Pull the black plastic piece toward the

connector. Hold the piece near the

connector. Pull the connector from the fuel

pipe.

If the connector and fuel pipe are stuck

together, jiggle the conn ector bac k and forth

to loosen the connector. Do not yank the

connector from the fuel pipe.

141RY00002

141RY00003

3. Tie a vinyl bag around the connector and

fuel pipe to protect them from dirt.

141RY00004

2. Joining the connector and fuel hose

1. Remove the vinyl bags from the connector

and fuel hose. Check that the contact

surfaces are undamaged and free of dirt and

other foreign material. Clean if necessary.

2. Align the axis of the fuel pipe and connector.

Push the connect or into the f uel pipe until a

distinct click is heard.

141RY00005

3. Gently pull on the c onnector to c heck that it

is securely la tched.

141RY00006

6. Disconnect transmission harness connector and

clip.

Conne ctor : Adapt er case, m ode sw itch , main ca se,

magnetic sensor, transfer switch, 2–4 actuator and

car speed sensor.

7. Remove harness heat shield.

815RW002

8. Support transmission with a jack.

Remove rear mount nuts from the third

crossmember.

F07RW008

9. Remove thi rd cross mem ber.

10. Disconnect transmission oil cooler pipes from A/T

side.

11. Remove oil pipe clamp and bracket from the

converter housing.

253RX002

12. R emo ve skid plate a nd loo sen oi l coo ler pipe clam p

bolt at the engine mount side.

13. Remove select cable by disconnecting inner cable

from select lever and removing outer cable with

bracket.

256RW025

14. Remove starter.

15. Remove under covers from the transmission and

engine.

16. Remove transfer control lever fixing bolts and push

up transfer control lever.

262RW015

17. Remove flex plate torque converter fixing bolts (6

pieces) by turning crankshaft.

240RX010

18. Remove engine-transmission fixing bolts.

19. Pull out transmission from the engine.

INSTALLATION

1. Slowly raise transmission jack until front of the

transm ission is aligned with rear of the engi ne. Join

the transmission to the engine.

2. Tighten engine-transmission bolts as shown in the

figure.

F07R200004

3. Align the flex plate torque converter bolt boss with

flex plate hole by turning the torque converter . Install

flex plate torque converter bolts (6 pieces) by

turning the crankshaft.

Torque: 54N•m

NOTE: Do not reuse the flex plate torque converter

bolt.

240RX010

4. Install transfer control lever on the transfer case.

262RW015

5. Install under covers to the transmission and engine.

Torque: 8N•m

6. Install starter.

Torque: 40N•m

7. Install select cable by connecting inner cable to

selec t leve r and ins talli ng oute r cable with bracket.

256RW025

8. Co nne ct tra ns mi ssio n oil co ole r pip es to A/T.

Torque: 44N•m

9. Install oil cooler pipe clamp and bracket to the

converte r housi ng.

253RX002

10. Tighten oil cooler pipe clamp bolt at the engine

mount side and install skid plate.

11. Install third crossmember.

Torque: 116N•m

12. Install rear mount nuts.

Torque: 50N•m

F07RW008

13. Install harness heat shield.

Torque: 6N•m

815RW002

14. Connect transmission harness connector and clip.

Conne ctor : Adapter ca se, mode swi tch, mai n case ,

transfer switch, 2–4 actuator and vehicle speed

sensor.

15. Connect fuel pipe to transmission side.

NOTE: See “NOTE" of removal steps.

141RY00007

240RW014

16. Install fuel pipe bracket to the third crossmember.

141RX004

17. Install center exhaust pipe.

Torque: 43N•m

18. Install transfer case guard.

150RX008

19. Install front propeller shaft and rear propeller shaft.

Torque: 63N•m

20. Connect battery ground cable.

SOLENOID (MAIN CASE VALVE BODY)

REMOVAL

1. Raise the vehicle and support it on jack stands.

2. Disconnect battery ground cable.

3. Drain fluid.

4. Remove sixteen 10 mm screws, main case oil pan,

magnet, and gasket.

5. Remove three 13 mm screws, oil filter.

6. Disconnect wiring harness from band control

solenoid and shift solenoids. Pull only on

connectors, not on wiring harness.

7. Remove spring pin for Shift Solenoid ‘A’, Shift

Solenoid ‘B’, and Band Control Solenoid

respectively, using suitable pliers taking care not to

damage solenoids.

210RW010

244RW003

8. Remove Shift Solenoid ‘A’, Shift Solenoid ‘B’, and

Band Control Solenoid, and gaskets from main case

valve body. Do not pull on wiring harness. Remove

solenoids by grasping the metal tip.

INSTALLATION

1. Install Shift Solenoid ‘A’, Shift Solenoid ‘B’, and

Band Control Solenoid with new gaskets to main

case valve body respectively.

2. Carefully install spring pin with hammer to avoid

damage to valve body, etc.

243RW004

3. Connect wiring harness to solenoids.

4. Install oil filter with a new gasket and the three 13

mm screws, tighten to the specified torque.

Torque: 20N•m

5. Install magnet, main case oil pan with new gasket,

and sixteen 10 mm screws. Tighten the screws to

the specified torque.

Torque: 11N•m

6. Fill transmission through the overfill screw hole of oil

pan, using ATF DEXRON®-III. Refer to Changing

Transmission Fluid in this section.

7. Connect battery ground cable.

SOLENOID (ADAPTER CASE VALVE BODY)

REMOVAL

1. Raise the vehicle and support it on jack stands.

2. Disconnect battery ground cable.

3. Drain fluid.

4. Remove adapter case oil pan twelve fixing 10 mm

screws, adapter case oil pan, and gasket.

NOTE: Oil pan still contains transmission fluid. Place a

large drain container under the oil pan and drain the

fluid carefully.

5. Disconnect wiring harness from Pressure Control

Solenoid and Converter Clutch Solenoid. Pull only

on connectors, not on wiring harness.

6. Remove 11 mm bolt and Converter Clutch Solenoid

with two O-rings.

210RW011

7. Remove 11 mm bolt, retainer, and Pressure Control

Solenoid.

210R100002

INSTALLATION

1. Install Pressure Control Solenoid, retainer, and 11

mm bolt to adapter case valve body. Tighten the bolt

to the specified torque.

Torque: 10 N•m

2. Install Converter Clutch Solenoid with two O-rings,

and 11 mm bolt to adapter case valve body. Tighten

the bolt to the specified torque.

Torque : 10N•m

3. Connect wiring harness assembly to solenoids.

4. Install adapter case oil pan, new gasket, and twelve

10 mm screws. Tighten the screws to the specified

torque.

Torque : 11N•m (96lbin)

5. Fill transmission through overfill screw hole oil pan,

using ATF DEXRON®-III. Refer to Changing

Transmission Fluid in this section.

6. Connect battery ground cable.

VALVE BODY ASSEMBLY (MAIN CASE)

REMOVAL

1. Raise the vehicle and support it on jack stands.

2. Disconnect battery ground cable.

3. Drain fluid.

4. Remove sixteen 10 mm screws, main case oil pan,

magnet and gasket.

5. Remove three 13 mm oil filter fixing screws, then

remove oil filter.

6. Remove two 13 mm manual detent fixing screws,

then remove roller and spring assembly.

7. Disconnect wiring harness from band control

solenoid and shift solenoids. Pull only on

connectors, not on wiring harness.

8. Remove four 13 mm servo cover fixing screws, then

remove servo cover and gasket.

9. Remove seven 13 mm valve body fixing screws.

10. Remove main case valve body with manual valve

link and transfer plate. Note the position of the link

(long end into valve, short end into range selector

lever).

11. Remove transfer plate gasket from main case.

12. Remove two check balls from main case.

INSTALLATION

1. Install two check balls to main case.

244RW002

2. I nspect electric al 7 way connector and seal of mai n

case. Replace if necessary.

3. Use two J–25025–B guide pin to install main case.

• Install valve body complete assembly and manual

valve link.

NOTE: Valve must be extended as the short end of

manual valve link is connected to the range selector

lever. Long end of link goes into valve.

4. Install seven 13 mm screws, and tighten them to the

specified torque.

Torque: 20N•m (15lbft)

243RS008

5. Remove two guide pins from main case.

6. Install servo cover gasket, cover, and four 13 mm

screws . Tight en t he scr ews to t he spec ified to rque .

Torque: 25N•m (18lbft)

7. Connect wiring harness to band control and shift

solenoids.

8. Install roller and spring assembly to manual detent.

• Install two 13 mm screws, and tighten them to the

specifi ed tor que .

Torque: 20N•m (15lbft)

9. Install oil filter and three 13 mm screws. Tighten to

the specified torque.

Torque : 20N•m (15lbft)

10. Install oil pan gasket, magnet, oil pan and sixteen 10

mm screws. Tighten the screws to the specified

torque.

Torque: 11N•m (96lbin)

11. Fill transmission through overfill screw hole of oil

pan, using ATF DEXRON®-III. Refer to Changing

Transmission Fluid in this section.

12. Connect battery ground cable.

VALVE BODY ASSEMBLY (ADAPTER CASE)

REMOVAL

1. Raise the vehicle and support it on jack stands.

2. Disconnect battery ground cable.

3. Drain fluid.

4. Remove twelve 10 mm adapter case oil pan fixing

screws, adapter case oil pan, and gasket.

NOTE: Oil pan still contains transmission fluid. Place a

large drain container under the oil pan.

Drain the fluid carefully.

5. Disconnect wiring harness from Pressure Control

solenoid and Converter Clutch Solenoid. Pull only

on connectors, not on wiring harness.

6. Remove seven 13 mm screws from adapter case

valve body assembly, then remove transfer plate,

two gaskets, and adapter case valve body.

INSTALLATION

1. Inspect electrical 4 way connector and seal of

adapter case. Replace if necessary.

2. Install gasket, transfer plate, and gasket.

3. Install adapter case valve body and seven 13 mm

screws. Tighten the screws to the specified torque.

Torque: 20N•m

4. Connect wiring harness assembly to Converter

Clutch Solenoid and Pressure Control Solenoid.

5. Install oil pan gasket, oil pan, and twelve 10 mm

screws. Tighten the screws to the specified torque.

Torque: 11N•m

6. Fill transmission through the overfill screw hole of oil

pan, using ATF DEXRON®-III, Refer to Changing

Transmission Fluid in this section.

7. Connect battery ground cable.

POWERTRAIN CONTROL MODULE (PCM)

REMOVAL

1. Disconnect battery ground cable.

2. Disconnect PCM wiring harness connectors from

PCM.

3. Remove PCM from bracket.

825R100018

INSTALLATION

1. Install PCM to bracket.

2. Connect PCM wiring harness connectors to PCM.

3. Connect battery ground cable.

SPEED SENSOR (EXTENSION HOUSING)

REMOVAL

1. Disconnect battery ground cable.

2. Remove front console.

3. Remove selector lever assembly.

241RW007

4. Disconnect speed sensor harness connector from

speed sensor.

5. Remove one 10 mm screw and speed sensor with

O-ring.

INSTALLATION

1. Inspect the speed sensor O-ring, and replace it if

necessary.

2. Install speed sensor assembly and 10 mm screw.

Torque: 9N•m

Connect speed sensor harness connector to speed

sensor.

3. Install selector lever assembly.

• Adjust shift lock cable.

Refer to Shift Lock Cable in this section.

4. Install front console.

5. Connect battery ground cable.

TRANSMISSION OIL TEMPERATURE SENSOR (MAIN CASE)

REMOVAL

1. Raise the vehicle and support it on jack stands.

2. Disconnect battery ground cable.

3. Drain fluid.

4. Remove sixteen 10 mm main case oil pan fixing

screws, main case oil pan, and gasket.

5. Disconnect wiring harness from shift solenoids,

band apply solenoid, and 7 way connector of main

case. Pull only on connectors, not on wiring

harness.

6. Remove wiring harness assembly with transmission

oil temperature sensor.

244RY001

INSTALLATION

1. Install wiring harness assembly with transmission oil

temperature sensor to band apply solenoid, shift

solenoids, and 7 way connector of main case.

2. Install oil pan gasket, oil pan and sixteen 10 mm

fixing screws. Tighten the screws to the specified

torque.

Torque: 11N•m

3. Fill transmission through the overfill screw hole of oil

pan, using ATF DEXRON®-III.

Refer to Changing Transmission Fluid in this

section.

4. Connect battery ground cable.

FRONT OIL SEAL (CONVERTER HOUSING)

REMOVAL

1. Remove transmission assembly from the vehicle

,refer to Transmission (With Transfer Case) in this

section.

2. Remove torque converter from converter housing.

3. Remove three screws and oil seal ring from

converter housing.

241RW008

INSTALLATION

1. Apply clean ATF to the new oil seal ring lip.

• Install oil seal ring to converter housing, tighten to

the specified torque.

Torque: 3N•m

2. Install torque converter to converter housing.

3. Install tran smissi on as se mbly to th e v eh ic le , r efer to

Transmission (With Transfer Case) in this section.

REAR OIL SEAL (EXTENSION HOUSING)

REMOVAL

1. Remove transfer case assembly from the vehicle.

Refer to Transfer Case in Drive Line/Axle section.

2. Remove rear oil seal from transmission extension

housing.

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INSTALLATION

1. Use J–36797 extension housing oil seal installer,

and install the rear oil seal to the transmission

extension housing.

2. Install the transfer case assembly to the vehicle.

Refer to Transfer Case in Drive Line/Axle section.

TRANSMISSION (4L30–E)

DISASSEMBLY

NOTE: During the disassembly and reassembly,

perform the following:

• Wash each part thoroughly, and blow air through

each oil passage and groove to eliminate blockage.

• Seal rings, roll pins, and gaskets should be replaced.

• When assembling the components, apply

DEXRON® -III Auto matic Transmission Fluid (ATF) to

each seal, rotating part, and sliding part.

• D o no t dip part faci ngs, such as clu tch o r brak e dri ve

plates, in cleaner when washing it.

Also, always coat parts with new ATF two or three

times after cleaning with solvent.

1. Remove torque converter (1).

• Drain fluid from torque converter.

• Attach J–8763–02 holding fixture to the

transmission and set it on J–3289–20 holding

fixture base.

NOTE: Do not overtighten the tool, as case damage

may result.

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2. Remove O-ring (2) from turbine shaft.

3. Remove two 10mm mode switch screws, selector

lever nut, cover, and mode switch (3).

4. Remove twelve 10mm adapter case oil pan (4)

fixing screws, adapter oil pan, and gasket.

5. Disconnect electrical wiring connections (5) from

solenoids and 4 way connector of adapter case. Pull

on connectors only, not on wiring harness.

6. Remove seven 13mm adapter case valve body (6)

fixing screws, adapter case valve body assembly,

transfer plate, and two gaskets.

• Remove wiring harness and 4 way connector.

7. Remove sixteen 10mm main case oil pan (7) fixing

screws, main oil pan, magnet, and gasket.

8. Remove three 13mm oil filter (8) fixing screws and

oil filter.

9. Remo ve two 13mm manual detent (9) fi xing screws,

roller and spring, and manual detent.

10. Disconnect wiring harness assembly (10) from band

apply solenoid, shift solenoids, and main case 7

way connector.

Pull on connectors only, not on wiring harness.

11. Remove four 13mm servo cover (11) fixing screws,

servo cover, and gasket.

12. Remove seven 13mm valve body screws from main

case.

• Remove wiring harness assembly (5) from the

adapter case side.

• Remove main valve body assembly (12) with

manual valve link and transfer plate. Note the

position of the li nk (long end into va lve, s hort end

into range selector lever).

• Remove 7 way connector.

• Remove gasket transfer plate from main case.

13. Remove two check balls (13) from main case.

240RY001

14. Turn transmission to vertical position to drain fluid.

Return back to horizontal position when drained.

• Install J–23075 servo piston spring compressor

with offset to the rear of case.

• Compress servo piston assembly.

• Remove servo piston retaining ring (14).

• Slowly release servo piston assembly (15).

• Remove tool.

15. Remove servo piston assembly (15), return spring

(16), and servo apply rod (17).

242RS002

16. R otate transmission to horizontal position, pan side

down.

• Remove one 10mm screw, and speed sensor

(18) with “O" ring.

17. Remove seven 8mm extension housing hexagon

socket head screws, extension housing assembly

(19), and gasket.

18. Remove retaining ring (20).

NOTE: Use extra long, needle nose pliers.

19. Remove speed wheel (21).

20. Remove wheel parking lock (with seal ring) (22).

241RS002

21. Rotate transmission to vertical position, converter

housing up.

• Loosen the converter housing and oil pump

assembly fixing screws, but do not remove, the

five 13 mm inner screws unless oil pump

disassembly is required.

• Remove seven outer screws.

• Remove converter housing and oil pump

assembly (23).

22. Remove gasket (24).

23. Remove selective thrust washer (25).

241RW004

24. Remove fourth clutch retainer (26).

25. Grasp turbine shaft and lift out the overrun clutch

housing assembly (27) and fourth clutch plates (28).

26. Remove thrust bearing assembly (29).

27. Remove overdrive internal gear (30).

28. Remove thrust washer (31).

252RS001

29. Re mov e a dap ter cas e a nd c en ter s upp or t ass emb ly

(with fourth clutch piston) (32).

30. Remove seal ring (33).

31. Remove selective thrust washer (34) and two O-ring

seals (35) from main case.

32. Use J–23327 and J–23327–90 compressor to

compress the fourth clutch spring retainer and

springs (37).

• Release snap ring (36) from groove.

• Remove clutch compressor and snap ring (36).

33. Remove retainer and spring assembly (37).

34. Insert two converter housing/main case screws to

hold adapter case while pulling out fourth clutch

piston (38).

• Remove fourth clutch piston assembly (38) from

the adapter case.

• Remove converter housing/main case screws.

35. Grasp intermediate shaft, twist and pull out the

second and third clutch drum assemblies with

reverse clutch plates while holding onto output shaft

(39).

36. Separate second (40) and third clutch (41)

assemblies.

37. Remove thrust washer (42).

38. Remove reverse clutch plates (43 and 44) and

reverse clutch pressure plate (45).

39. Remove bearing (46) and washer (47).

40. Remove planetary carrier assembly (48).

41. Remove thrust bearing (49).

42. Remove reaction sun gear (50)

43. Remove needle bearing (51).

44. Remove brake drum (52).

45. Remove brake band (53).

46. Remove thrust bearing (54).

242RS003

47. Rotate case to horizontal position, valve body side

facing up.

• Remove spring pin (55), using cutting pliers, then

remove parking lock and selector lever assembly

(56).

NOTE: Insert wire in the center of the spring pin to

prevent it from collapsing during removal. Be aware of

pin height. Protect machined face of main case.

48. Remove parking lock and range selector lever 17

mm nut (57).

49. Remove parking lock and range selector lever (56),

and actuator assembly.

50. Remove selector shaft (58).

NOTE: Inspect the shaft for burrs before removing to

prevent damaging seal. If necessary, remove burrs by

lightly sanding with an oilstone.

249RS004

REASSEMBLY

1. Inspect selector shaft seal and replace it if

necessary.

NOTE: Use a seal installer when replacing the seal.

• Install selector shaft.

NOTE: Spring pin groove must be positioned inside the

case.

2. Install spring pin. Be sure the selector shaft can

move freely. Do not push the pin flush with the

case surface. Leave enough height for removal.

3. Install actuator assembly (1).

4. I nstall parki ng lock and range sel ector lever (2 ) and

new 17 mm nut. Tighten the nut to the specified

torque.

Torque: 22N•m

249RS005

5. R otate mai n case to ver tical position , extens ion en d

facing down.

• Install brake band assemb ly (3) .

NOTE: Be sure to align servo pin area with the servo

hole.

6. Install thrust bearing (4).

NOTE: The case b ushin g ac ts as a gu ide f or th e thru st

bearing.

7. Install br ake drum (5).

8. Install reaction sun gear (6).

9. Install needle bearing (7).

10. In spect planetary ca rrier assembly (8) for wear and

damage. If necessary replace it.

• Measure pinion end play clearance with a feeler

gauge.

Clearance: 0.13mm–0.89mm

If clearance is outside specified value, replace the

planetary carrier assembly.

248RS001

11. Install the thrust bearing (9) on the output shaft.

NOTE : Use petr oleum jel ly to hold the thrus t bearing in

place.

12. A lign planetary p inions. Each pinio n is marked with

double points to indicate the master tooth space and

exactly opposite with a single point to indicate the

master tooth. The markings on the planetary carrier

consist of doubl e lines which ar e to be lined up with

the double points on two opposite pinions; the single

lines ar e to be lined up with the sin gle points on the

other two pinions.

• After all four pinions are lined up, slide on the

third clutch assembly. Rotate third clutch and

check mark alignment. Considering that the ring

gear tooth between the double points of one

planetary pinion is tooth number 1, count the

teeth to check that the single points on the two

adjacent pinions are between teeth 23 and 24 of

the ring gear, and that the ring gear tooth

between the double points of the opposite pinion

is tooth number 46. If the ring gear and pinions

are not lined up, remove and realign them.

13. Install planetary carrier (8) with third clutch (12).

NOTE: Do not force. When properly aligned, the parts

will fit together easily.

14. Remove the third clutch (12). Install bearing (11)

and washer (10).

NOTE: Use petroleum jelly to hold the washer and

bearing in pla ce .

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15. Carefully align the second clutch plate inner tangs.

• Install thrust washer, tangs pointing downward,

and locating tang positioned in slot on second

clutch hub.

NOTE: Use petroleum jelly to hold thrust washer in

place.

16. Install third clutch and intermediate shaft assembly

(13) into the second clutch drum (14).

17. Install second and third clutch assemblies into the

main case. Twist output shaft and clutch

assemblies to ensure proper fit.

247RS001

18. Install pressure plate (15) with lip side up, tang

facing valve body face.

19. Install reverse clutch plates. Start with a steel plate

(17) and alternate with a lined plate (16).

20. Install waved clutch plate (18) with center tang

facing valve body side.

247RS002

21. Second clutch end play measurement

1. Install t he J–23085–A s electiv e washer gauging

tool (with spacer ring) on the case flange and

against the intermediate shaft.

2. Position the inner shaft of the gauging tool

against the thrust surface of the second clutch

hub.

3. Tighten thumb screw. Remove the tool.

4. Fit the spacer ring on the inner shaft of the tool.

5. Measur e t he gap an d s elec t a ppr op riate wa sh er

as shown in the chart.

247R100001

247RS004

Sele ctive Thrust Washer

Gap: mm(in) Color

1.53 – 1.63 Yellow

1.72 – 1.82 Red

1.91 – 2.01 Black

2.10 – 2.20 Natural

2.29 – 2.39 Green

2.48 – 2.58) Blue

FOLLOWING THE PROCEDURE SHOULD RESULT

IN FINAL END–PLAY FROM 0.36 mm TO 0.79 mm

22. Inspect fourth clutch piston seals and replace if

necessary.

• Lubricate J–38554 fourth clutch piston fitter and

install it on fourth clutch piston (19).

• Install fourth clutch piston (19) in adapter case

(20).

• Remove fitter.

252RS003

23. Install retainer and spring assembly (22) into fourth

clutch piston (21).

24. Install snap ring (23) in adapter case.

• Install J–23327 and J–23327–90 fourth clutch

spring compressor.

• Seat snap ring in groove.

• Remove compressor.

252RW002

252RS004

25. Install selective washer using petroleum jelly.

26. Install two O-ring seals (24) in main case and

adapter case/main case seal ring (25).

27. Install J–38588 guide pins.

• I nstall ad apter ca se and ce nter s upp ort as s emb ly

to main case.

242RS004

28. Install thrust washer (26) into adapter case, with

tangs pointing downwards.

29. P reass emble o verdri ve inter nal ge ar (27) and thrus t

bearing assembly (28) onto the turbine shaft and

overrun clutch assembly.

NOTE: Install bearing assembly, black side up. Use

petroleum jelly to keep assembly in place.

30. Install overdrive carrier (30) and internal gear

assembly into adapter case.

31. Install fourth clutch plates (29) in the following order:

Steel, Lined, Steel, Steel , Lined, St eel. Steel plates

go in with short tang facing towards valve body

surface.

32. Install fourth clutch retainer(31) with the notch facing

up and positioned towards valve body surface.

252RW004

33. Overdrive clutch end play measurement

1. Install t he J–23085–A s electiv e washer gauging

tool on the adap ter case flange and again st the

input shaft.

2. Position the inner shaft of the tool against the

thrust surface of the overrun clutch housing.

3. Tighten thumb screw. Remove the tool.

4. Measure gap. Select appropriate size washer

as shown in the chart.

5. Set selective thrust washer aside.

252RS005

252RS006

34. Install selective washer (32).

NOTE: Use petroleum jelly to hold selective washer in

place.

35. Install gasket (33).

Sele ctive Thrust Washer

Gap: mm Color

1.53 – 1.63 Yellow

1.72 – 1.82 Red

1.91 – 2.01 Black

2.10 – 2.20 Natural

2.29 – 2.39 Green

2.48 – 2.58 Blue

FOLLOWING THE PROCEDURE SHOULD RESULT

IN FINAL END–PLAY FROM 0.1 mm TO 0.8 mm

36. Install converter housing and oil pump assembly

(34) to adapter case.

• Fit and tighten seven outer 13 mm screws.

Torque: 39N•m (29lbft)

• Ensure free rotation of pump using J–23082–01

pump rotation tool.

241RW010

37. Overdrive clutch end play measurement

1. Fit J–25 022 and J–24773–1 turbin e shaft puller

on turbine shaft.

2. Position axial play checking tool on converter

housing mating face.

3. Pull turbine shaft upwards with puller until first

resistance is met. (due to weight of overdrive

assembly)

4. Maintain shaft in this position and set indicator

to zero.

5. Pull turbine shaft further upwards with puller.

Read end play shown on indicator.

End play: 0.1mm – 0.8mm Remove axial play

checking tool and puller.

NOTE: If end play is not correct, repeat selective

washer selection.

252RW001

38. Inspect extension housing oil seal and replace if

necessary, using J–36797 extension housing oil

seal installer.

• Rotate transmission to horizontal position, with

valve body side down.

• Inspect parking wheel seal ring. Replace if

necessary.

• Install wheel parking lock assembly (35).

39. Install speed wheel (36) and snap ring (37).

NOTE: Use extra long, needle nose pliers.

40. Install gasket onto extension assembly with a thin

coating of oil.

• Install extension housing assembly (38), and

align parking pawl shaft.

• Install actuator assembly into extension

assembly.

• Install seven 8 mm hexagon socket head screws.

Torque: 32N•m

Inspect speed sensor O-ring. Replace if necessary.

• Install speed sensor assembly (39) and 10 mm

screw.

Torque: 9N•m (78lbin)

241RW009

241RS004

41. Main case end play measurement

1. Attach axi al play c hecking t ool on th e extens ion

housing and set indicator to zero on output

shaft.

2. Manually push output shaft upwards.

End play: 0.36mm – 0.80mm

Remove axial play checking tool.

3. If end play is not correct, repeat selective

washer selection.

241RS005

42. Inspect servo piston seal ring. Replace if

necessary.

• Ensure brake band is correctly positioned.

Rotate output shaft if necessary.

• Install J–38428 servo piston fitter in servo bore.

• Install apply rod (40), round end toward band,

return spring (41) and piston assembly (42).

43. Install the J–23075 servo spring compressor with

offset to rear of case.

• Compress servo piston seal ring, using fitter while

tightening the tool screw.

• Install servo piston retaining ring (43).

• Remove tool.

• Adjust the brake band by tightening the servo

adjusting screw to 4.5 N·m (39.8lbin) torque. Be

certain the lock nut is loose, then back-off the

screw five turns exactly. Hold piston sleeve with

wrench and tighten lock nut to 18.5 N·m torque.

Be certain the adjusting screw does not turn.

242RW004

44. Install two check balls (44).

244RW002

45. Inspect main case electrical connector and seal,

replace if necessary.

• Install electrical 7 way connector/main case and

wiring harness.

46. Install two J–25025–B guide pins into main case.

• Install main case valve body complete assembly

(45) and manual valve link.

NOTE: Valve must be extended as the short end of

manual valve link is connected to the range selector

lever. Long end of link goes into valve.

• I nstall seve n 13 mm screw s, tighte n the spec ified

torque.

Torque: 20N•m

• Remove two guide pins.

47. Install servo cover gasket, cover (46) and four 13

mm screws.

Torque: 25N•m

48. Connect wiring harness (47) to band control, shift

solenoids, and main case 7 way connector.

49. Install manual detent roller and spring assembly

(48) with clip.

• Install two 13 mm screws.

Torque: 20N•m

50. Install oil filter (49) and three 13 mm screws.

Torque: 20N•m

51. Install oil pan gasket, magnet, main oil pan (50),

sixteen 10 mm screws.

Torque: 11N•m

52. Inspect adapter case electrical connector and seal.

Replace if necessary.

• Install electrical 4 way connector and harness

assembly (52) in bottom of adapter case.

53. Install gasket, transfer plate, and gasket.

• Install adapter case valve body (51) complete

and seven 13 mm screws.

Torque: 20N•m

54. Connect wiring harness harness assembly (52) to

Converter Clutch Solenoid, Pressure Control

Solenoid, and 4 way connector.

55. Install oil pan gasket, adapter case oil pan (53), and

twelve 10 mm screws.

Torque: 11N•m

• Rotate transmission, with bottom pan facing

down.

56. Install mode switch (54), two 10 mm screws,

selector lever nut, and cover.

10 mm screw

Torque: 13N•m

Nut

Torque: 23N•m

• Adjust using setting tool, refer to Mode Switch in

this secti on .

57. Install O-ring (55) on turbine shaft.

58. Install torque converter (56).

The converter assembly must be replaced under

any of the following conditions:

a Evidence of damage to the pump assembly.

b Metal particles are found after flushing the

cooler lines.

c External leaks in hub weld area.

d Converter pilot broken, damaged, or poor fit into

crankshaft.

e Converter hub scored or damaged.

f Internal failure in stator.

g Contamination from engine coolant.

h Excess end play.

• Rotate transmission, bell housing up. Spin

converter to insure proper fit.

59. Fill transmission through the overfill screw hole of oil

pan, using ATF DEXRON®-III. Refer to Changing

Transmission Fluid in this section.

240RY002

CONVERTER HOUSING AND OIL PUMP ASSEMBLY

DISASSEMBLED VIEW

241RW003

EndOFCallout

DISASSEMBLY

1. Remove oil pump assembly from converter housing.

2. Remove outer seal ring.

3. Remove gasket.

4. Remove wear plate.

5. Remove oil seal ring.

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation, or local wear is found in a

converter housing, outer seal ring, wear plate, or oil seal

ring, replace it.

REASSEMBLY

1. Install wear plate onto oil pump assembly.

2. Install converter housing onto complete oil pump

assembly. Align with two short J–38588 guide pins

on outer bolt holes.

• Loosely install five 13mm bolts.

• Center converter housing using J–38557

centering tool.

• Tighten five inner 13mm bolts in an alternating

pattern.

Torque: 20N•m

241RW002

3. Install oil seal ring (3 screws).

Torque: 3N•m

4. Install gasket.

5. Install outer seal ring.

Legend

(1) Converter Housing

(2) Outer Seal Ring

(3) Gasket

(4) Wear Plate

(5) Oil Pump Assembly

(6) Oil Seal Ring

OIL PUMP

DISASSEMBLED VIEW

241RS014

EndOFCallout

DISASSEMBLY

1. Remove oil pump drive gear (1) and driven gear (2).

2. Remove pin (3) from oil pump assembly (18).

3. Remove plug (4), spring (5), and converter clutch

control valve (6).

4. Remove snap ring (7) from oil pump assembly (18).

5. Remove spring seat (8), spring (9), and throttle

signal accumulator piston (10).

6. Remove sleeve pin (11) from oil pump assembly

(18).

7. Remove sleeve (12), boost valve (13), spring seat

(14), valve spring (15), spring seat (16), and

pressure regulator valve (17).

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation or wear is found, replace

the damaged part.

REASSEMBLY

1. Lubricate and preinstall pressure regulator spring

seat (16) on valve (17), with the flat side against

shoulder.

2. In stall pressure re gulator valv e (17) and spring seat

(16) assembly, valve spring (15), and spring seat

(14) with the flat side away from spring to oil pump

assembly (18).

3. Assemble boost valve (13) into sleeve (12).

4. In stall bo os t v alve an d s le ev e a ssem bl y, and s lee ve

pin (11) to oil pump assembly (18).

5. In stall thr ottle signa l accum ula tor pis ton (10 ), spr ing

(9), and s pring s eat ( 8), with t he flat side away from

the spring, and snap ring (7) to oil pump assembly

(18).

6. Install converter clutch control valve (6), spring (5),

plug (4), and pin (3) to oil pump assembly (18).

7. Install oil pump driven gear (2) and drive gear (1).

Legend

(1) Oil Pump Drive Gear

(2) Oil Pump Driven Gear

(3) Pin

(4) Plug

(5) Spring

(6) Converter Clutch Control Valve

(7) Snap Ring

(8) Spring Seat

(9) Spring

(10) Throttle Signal Accumulator Piston

(11) Sleeve Pin

(12) Sleeve

(13) Boost Valve

(14) Spring Seat

(15) Valve Spring

(16) Spring Seat

(17) Pressure Regulator valve

(18) Oil Pump Assembly

MAIN CASE VALVE BODY

DISASSEMBLED VIEW

244RS010

EndOFCallout

DISASSEMBLY

1. R emo ve two 11m m bolts from v alve b ody (28) , then

remove gaskets and transfer plate (1).

2. Remove manual valve (2).

3. Push in band control solenoid (3) to compress

waved washer (5), and remove pin (4).

4. Remove band control solenoid (3) and waved

washer (5).

5. Remove spring pin (6) with a 3 mm diameter punch.

6. Remove solenoid A (7) by grasping the metal tip. Do

not grasp the connector housing.

7. Remove retainer (8), 1–2/3–4 shift valve (9) and

spring (10).

Legend

(1) Gaskets and Transfer Plate

(2) Manual Valve

(3) Band Control Solenoid

(4) Pin

(5) Waved Washer

(6) Spring Pin

(7) Solenoid A

(8) Retainer

(9) 1–2/3–4 Shift Valve

(10) Spring

(11) Spring Pin

(12) Solenoid B

(13) Retainer

(14) 2–3 Shift Valve

(15) Spring

(16) Spring Pin

(17) Plug

(18) Spring

(19) Low Pressure Control Valve

(20) Spring Pin

(21) Plug

(22) Band Control Screen Assembly

(23) Spring Pin

(24) Plug

(25) 1–2 Accumulator Valve

(26) 1–2 Accumulator Control Valve

(27) Check ball

(28) Main Case Valve Body

8. Remove spring pin (11) with a 3 mm diameter

punch.

9. Remove solenoid B (12) by grasping the metal tip.

Do not grasp the connector housing.

10. Remove retainer (13), 2–3 shift valve (14), and

spring (15).

11. Remove spring pin (16), plug (17), spring (18) and

low pressure control valve (19).

12. Remove spring pin (20), plug (21), and band control

screen assembly (22).

13. Remove spring pin (23), plug (24), 1–2 accumulator

valve (25), and 1–2 accumulator control valve (26).

14. Remove 1 check ball (27) from valve body (28).

INSPECTION AND REPAIR

Inspect for the following, and replace any damaged or

worn parts:

1. Damage or wear to each valve.

2. Damage in oil passeges.

3. Cracks or damage to valve body.

4. Valve operations.

5. Spring fatigue.

REASSEMBLY

1. Install 1–2 accumulator control valve (26), 1–2

accumulator valve (25), plug (24), and spring pin

(23).

2. Install band control screen assembly (22), plug (21),

and spring pin (20).

3. Install low pressure control valve (19), spring (18),

plug (17), and spring pin (16).

4. I ns tall spri ng (15) , 2–3 shift va lv e ( 14), r etainer (1 3),

solenoid B (12), and spring pin (11).

5. Install spring (10), 1–2/3–4 shift valve (9), retainer

(8), solenoid A (7), and spring pin (6).

6. I nstall waved washer (5), band co ntrol solenoid (3),

and pin (4).

7. Install manual valve (2).

8. Install check ball (27) to valve body (28).

9. Install gasket (valve body/transfer plate) and

transfer plate using two J–3387–2 guide pins.

• Install two 11mm bolts.

Torque: 13N•m

244RS004

• Install gasket (transfer plate/main case).

ADAPTER CASE VALVE BODY

DISASSEMBLED VIEW

243R100001

EndOFCallout

DISASSEMBLY

1. Remove 11mm bolt from valve body.

• Remove converter control solenoid assembly

(1).

2. Remove 11mm bolt and retainer (2) from valve

body.

• Remove Pressure Control Solenoid (3).

3. Remove retainer (4), plug (5), 3/4 accumulator valve

(6), and 3/4 accumulator control valve (7)

4. Remove spring (8), retaining ring (9), and feed limit

valve (10).

5. Remove plug retainer (11), O-ring (12), plug (13),

and Pressure Control Solenoid screen assembly

(14).

• Use 5 mm bolt to pull plug.

INSPECTION AND REPAIR

Inspect for the following, and replace any damaged or

worn parts:

1. Damage or wear to each valve.

2. Damage in oil passeges.

3. Cracks or damage to valve body.

4. Valve operations.

5. Spring fatigue.

Legend

(1) Converter Clutch Solenoid Assembly

(2) Retainer

(3) Pr ess ure Control Sol eno id

(4) Retainer

(5) Plug

(6) 3/4 Accumulator Valve

(7) 3/4 Accumulator Control Valve

(8) Spring

(9) Retaining Ring

(10) Feed Iimit Valve

(11) Plug Retainer

(12) O-ring

(13) Plug

(14) Pressure Control Solenoid Screen Assembly

(15) Adapter Case Valve Body

REASSEMBLY

1. Install Pressure Control Solenoid screen assembly

(14), plug (13), O-ring (12), and plug retainer (11).

2. Install feed limit valve (10), retaining ring (9), and

spring (8).

3. Install 3/4 accumulator control valve (7), 3/4

accumulator valve (6), plug (5), and retainer (4).

4. Install Pressure Control Solenoid (3).

• Pl ace solenoi d termin als pointing towards matin g

face.

• Install retainer (2) and bolt.

Torque: 10N•m

5. Install converter clutch solenoid assembly with two

O-rings (1) to valve body.

• Install bolt.

Torque: 10N•m

THIRD CLUTCH AND SPRAG UNIT

DISASSEMBLED VIEW

248RW001

EndOFCallout

DISASSEMBLY

1. Place the third clutch drum and intermediate shaft

assembly upright, using the overdrive internal gear

as a support.

2. Locate the ends of the retaining ring. Depress one

end of the ring u sing a small screwdriver instead of

the depressor handle provided with the tool

J-384 50-A. Slide one bl ade down between t he third

clutch drum and the retaining ring.

3. Remove a screwdriver and repeat this step for the

other end of retaining ring.

4. Install the remaining four blades approximately

(five) notches apart using a screwdriver to depress

the retaining ring.

5. Pull up on input sun gear and sprag unit assembly

(1 and 2) to release the retaining ring from third

clutch drum assembly (8).

6. Remove the tool blade s. 248RX001

7. Remove retaining washer (3), bearing (4), thrust

washer (5), and clutch plates (6 and 7) from the third

clutch drum assembly (8).

Legend

(1) Retaining Ring

(2) Input Sun Gear and Sprag Unit Assembly

(3) Retaining Washer

(4) Bearing

(5) Thrust Washer

(6) Clutch Plates

(7) Third Clutch Spring Cushion Plate

(8) Third Clutch Drum Assembly

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation or wear is found, replace

the damaged part.

REASSEMBLY

1. Place third clutch drum and intermediate shaft

assembly upright, using the overdrive internal gear

as a support.

2. Install third clutch spring cushion plate (7), bevel

face down.

3. Install third clutch plates (6) into third clutch drum

assembly (8). Start with the steel clutch plate and

alternate with lined plates.

4. Install thrust washer (5), bearing (4) and retaining

washer (3).

5. Fully engage the hub spline of the input sun gear

and sprag unit assembly (2) into the third clutch

inner tangs.

• Simultaneously rotate the outer sprag race to

engage into the third clutch drum assembly (8).

6. Place J-38450-A blades between the retaining ring

and the third clutch drum apporximately (five)

notches apart, and one blade at each end of the

retaining ring (1). Push down on sprag assembly

until the assembly is seated into the third clutch

drum assembly (8).

7. Remove the tool blades and engage retaining ring

into groove of third clutch drum.

248RX002

THIRD CLUTCH

DISASSEMBLED VIEW

248RS006

EndOFCallout

DISASSEMBLY

1. Compress spring seat using the J–23075 spring

compressor and J–23075–12 adapter tool.

NOTE: Do not overstress the springs and seat. This will

cause damage to the spring seat.

• Remove the tool.

• Remove retaining ring (1).

248RS007

2. Release the spring seat (2).

NOTE: Do not let the spring seat catch in the ring

groove.

• Remove spring seat (2) and springs (3).

3. Remove piston assembly (4) from third clutch drum

(5).

INSPECTION AND REPAIR

Visual check:

If any damage, deformation or wear is found, replace

the damaged part.

Operation check:

Shake the piston and listen for check ball movement.

Movement indicates proper check ball operation.

Replace the piston if the check ball is missing or falls

out.

Legend

(1) Retaining Ring

(2) Spring Seat

(3) Springs

(4) Piston As se mb ly

(5) Third Clutch Drum

REASSEMBLY

1. The lip of the piston seal must point toward the front

of the transmission. Lubricate the seal lip with

transmission fluid.

• Install piston assembly (4) into the third clutch

drum (5). Use the J–23084 third clutch piston

installer to protect the outer seal during

installation.

• Remove the seal installer.

248RS008

2. Install twelve springs (3) and spring seat (2).

3. Place retaining ring (1) onto spring seat.

• Compress the piston springs, using the J–23075

piston spring compressor and J–23075–12

adapter.

CAUTION: Do not overstress the springs and seat.

Do not let the spring seat catch in the ring groove.

This may cause damage to the spring seat.

• Install spring seat retaining ring (1).

• Remove the piston spring compressor and

adapter.

SPRAG UNIT

DISASSEMBLED VIEW

248RS009

EndOFCallout

DISASSEMBLY

1. Remove the sprag outer race, retaining ring, and

sprag assembly from the third clutch hub and sun

gear assembly.

2. Remove the rings and sprag assembly from the

sprag outer race.

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation or local wear is found,

replace the damaged part.

REASSEMBLY

NOTE: Flared shoulder of the sprag cage faces the sun

gear. This procedure must be followed exactly to be

sure that the sprag assembly is installed properly.

1. Install rings and sprag assembly onto the third

clutch hub and sun gear.

2. I nstall sprag ou ter race and retaini ng ring assemb ly

over the sprag cage assembly.

• Pl ace thir d clutch hub and su n gear ass embly o n

a flat surface, sun gear facing up. Place sprag

outer race an d sprag asse mbl y ov er the sun gear

assembly, push down and turn the input sun

counterclockwise at the same time.

NOTE: Check correct rotation by holding the sun gear

in your left hand and turning the outer race. The outer

sprag race should turn freely towards you and should

lock turning away from you.

248RS010

Legend

(1) Retaining Ring

(2) Spr ag Ou ter Race

(3) Ring

(4) Sprag Assembly

(5) Ring

(6) Third Clutch Hub and Sun Gear Assembly

SECOND CLUTCH

DISASSEMBLED VIEW

247RW001

EndOFCallout

DISASSEMBLY

1. Remove retaining ring (1) from second clutch drum

(11).

2. R emo ve ring gear (2), retaining rin g (3), and s pacer

(4).

3. Remove clutch plates (5) and waved washer (6).

4. Remove retaining ring (7) using J–23327

compre ssor to compress the spring seat (8).

Legend

(1) Retaining Ring

(2) Ri ng Ge ar

(3) Retaining Ring

(4) Spacer

(5) Clutch Plates

(6) Waved Washer

(7) Retaining Ring

(8) Spring Seat

(9) Springs

(10) Piston Assembly

(11) Sec ond Clu tch Drum

5. Remove spring seat (8), springs (9) and piston

assembly (10) from second clutch drum (11).

247RS006

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation or wear is found, replace

the damaged part.

Operation Check:

Shake the piston and listen for check ball movement.

Movement indicates proper check ball operation.

Replace the piston if the check ball is missing or falls

out.

REASSEMBLY

1. Install piston assembly (10) into the second clutch

drum (11).

• Lubricate the lip seal with transmission fluid.

Use the J–23080–A second clutch piston installer

to protect the outer piston lip seal.

NOTE: Lip of the seal should point toward front of

transmission.

• Remove the installer.

247RS007

2. In stall twenty -two piston s prings ( 9) and spr ing seat

(8) on the second clutch piston (10). Place retaining

ring (7) onto spring seat.

• Use the J–23327 compressor to compress the

piston springs.

NOTE: Do not let spring seat catch in ring groove.

• Remove the compressor.

3. Install waved plate (6) and clutch plates (5). Start

with a steel plate and alternate with lined plates.

• Align second clutch inner tangs.

4. Install spacer (4), with the fluted end toward clutch

plates.

5. Install retaining ring (3), ring gear (2) and retaining

ring (1).

3–4 ACCUMULATOR PISTON

DISASSEMBLED VIEW

244RS005

EndOFCallout

DISASSEMBLY

1. Install the J–38559–A cover compressor on adapter

case.

• Compress piston cover then remove snap ring.

242RS007

2. Install the J–41096 cover remover and J–38584

adapter to center hole of cover.

• Use the J–23907 slide hammer to remove cover.

3. Remove spring and piston assembly.

242RW001

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation or wear is found, replace

the damaged part.

Legend

(1) Snap Ring

(2) Cover

(3) Spring

(4) Piston As se mb ly

REASSEMBLY

1. Place the J–38553 piston fitter into adaptor case

and push the piston into position, using suitable

diameter tube.

• Remove the piston fitter.

244RS006

2. Install spring and cove r.

3. Install snap ring, using the J–38559–A compressor

tool.

• Install snap ring in groove.

• Remove the compressor tool.

242RS007

REVERSE CLUTCH PISTON AND CENTER SUPPORT

DISASSEMBLED VIEW

242RY001

EndOFCallout

Legend

(1) Retaining Ring

(2) Spring Seat

(3) Springs

(4) Piston Assembly

(5) Center Support

(6) Gasket

(7) Transfer Plate

(8) Gasket

(9) Restrictor

(10) Retainer Plate

(11) Plug

(12) Spring

(13) Overrun Lock Out Valve

(14) Retainer Plate

(15) Plug

(16) Spring

(17) Reverse Lock Out Control Valve

DISASSEMBLY

1. Install the J–23327 compressor tool on spring seat,

then compress the spring seat.

• Remove retaining ring (1).

NOTE: Do not over-stress the springs and seat, as this

will cause damage to the spring seat.

• Remove the compressor tool.

247RS008

2. Remove spring seat (2) and springs (3).

3. Remove piston assembly (4).

4. Remove 8 bolts from center support (5), then

remove center support (5) from adapter case.

5. Remove gasket transfer plate/outer support (6),

center support transfer plate (7), and gasket transfer

plate/adapter case (8).

6. Remove restrictor (9) from adapter case housing.

7. Remove retainer plate (10), plug (11), spring (12),

and overrun lock out valve (13) from center support

(5).

INSPECTION AND REPAIR

Visual Check:

If any damage, deformation or wear is found, replace

the damaged part.

REASSEMBLY

1. In stall ov errun lo ck ou t valv e (13 ) and spr ing ( 12) to

center support.

NOTE: Ensure correct assembly of valve. The spring

should be located over the long small diameter end.

2. Install plug (11) and retainer plate (10).

3. Place restrictor (9) in the lube overdrive channel in

the adapter case housing.

242RS005

4. In stall gas ket tran sfer plate/adap ter c ase (8), center

suppor t transf er pl ate (7) , and gaske t tran sfer pl ate/

center support (6).

5. Install center support (5) with 8 bolts.

Torque : 25N•m (18lbft)

6. Install piston assembly (4) into center support (5).

7. Install twenty four springs (3), spring seat (2), and

retaining ring (1 ).

• Install the J–23327 compressor and compress

spring seat (2) and springs (3), then seat snap

ring (1) in groove.

• Remove the tool.

OVERRUN CLUTCH AND TURBINE SHAFT

DISASSEMBLED VIEW

252RW005

EndOFCallout

Legend

(1) Snap Ring

(2) Overdrive Carrier Assembly

(3) Sun Gear

(4) Turbine Shaft

(5) Snap Ring

(6) Bac ki ng Pl ate

(7) Clutch Plates

(8) Snap Ring

(9) Overrun Roller Clutch C am

(10) Roller Clutch Assembly

(11) Overr un Clutch Release Spring Retainer

(12) Diaphragm Spring

(13) Piston Assembly

(14) Overrun Clutch Drum

(15) Turbine Shaft Seal Rings

DISASSEMBLY

1. Position overrun clutch assembly upright, using the

overdrive internal gear as a support.

• Remove snap ring (1).

252RS009

2. Remove overdrive carrier assembly (2), sun gear

(3) and turbine shaft (4).

3. Remove snap ring (5), backing plate (6), and clutch

plates (7).

4. Compress diaphragm spring with the J–23327–91

compressor then remove snap ring (8).

252RS010

5. Remove overrun roller clutch cam (9) and roller

clutch assembly (10).

6. Remove overrun clutch release spring retainer (11)

and diaphragm spring (12).

7. Remove piston assembly (13) from overrun clutch

drum (14).

8. Remove turbine shaft seal rings (15).

INSPECTION AND REPAIR

Overdrive Carrier Check

• Check pinion end play with a feeler gauge.

Clearance: 0.24mm–0.64mm (0.0094in–0.025in)

If clearance is outside specified value, replace overdrive

carrier assembly.

252RS011

Visual Check:

If any damage, deformation or wear is found, replace

the damaged part.

REASSEMBLY

1. Install turbine shaft seal rings (15) with grease

(petroleum jelly).

241RS008

2. Instal l the J –3855 5 inne r inst all er on the dr um (14) .

• Pre-install piston assembly into J–38555 outer

installer.

• Install overrun clutch piston assembly (13). Use

the outer installe r while pushing piston into drum

(14).

• Remove the installer.

252RS012

252RS013

3. I n stall diaph ra gm sp ring (1 2).

4. Install overrun clutch release spring retainer (11) (lip

faces upw ards), overrun roller clutch assembly (10)

and cam (9).

5. Place snap ring loosely on spring retainer.

• Hold the J–23327–91 compressor in a vise and

compress piston return spring with compressor.

• Set snap ring (8) in ring groove.

• Remove the compressor.

6. Install clutch plates (7), start with steel plate and

alternate with lined plates.

7. Install backing plate (6).

8. Install snap ring (5).

9. Install overdrive sun gear with countersink pointing

downwards.

10. Install the overdrive carrier assembly (2).

NOTE: Turn the assembly in a counter-clockwise

direction only until roller clutch enters the outer race.

After Installation, rotate the assembly and listen for

loose rollers.

11. Install turbine shaft (4) and snap ring (1).

MAIN DATA AND SPECIFICATION

General Specifications

Remarks

Model THM 4L30–E

Engine V6 3.2L 6VD1

Type Automatic four speed overdrive in

4th gear lockup clutch torque

converter

Control systems

Shift control Hydraulic

Shift pattern Electronic

Shift quality Electronic

Lockup cl utc h Electronic

Gear ratio

1st 2.856

2nd 1.618

3rd 1.000

4th (O/D) 0.723

Reverse 2.000

Gear set Noiseless, high torque capability

Oil used Name ATF DEXRON®–III

Q'ty liter (qt) 8.6 (9.1)

Torque converter 2,100 ± 150 Stall speed (rpm)

Reve rs e cl ut c h RC 5

Number of discs

Second clutch C2 6

Third clutch C3 6

Brake band Double wrap

Fourth clutch C4 2 Number of discs

Overrun clutch OC 1

Overdrive roller clutch OFW 10 Number of rollers

Principle sprag assembly PFW 26 Number of sprags

Ravigneaux type

gear train

(planetary gear

set)

Input sun gear 30

Number of teeth

Pinion gear 19

Long pinion 23

Ring gear 90

Long pinion 19

Output sun gear 46

Overdrive carrier

(planetary gear

set)

Sun gear 31

Pinion gear 24

Ring gear 81

Torque Specifications

E07R100005

E07RY003

E07R100004

SPECIAL TOOLS

ILLUSTRATION TOOL NO.

TOOL NAME

J–23075

Spring compressor (For

servo piston)

J–38450–A

Third clutch snap ring

compressor

J–23075–12

Third clutc h spr i ng

compressor adapter (Use

with J–23075)

J–23084

Third clutch piston

installer

J–23327

Third clutc h spr i ng

compressor

J–23080–A

Second clutch piston

installer

J–23085–A

Selective washer gaging

tool

J–23327–90

Fourth clutch spring

compressor (Use with J–

23327)

J–38553

3/4 accumulator piston

fitter

J–41096

Cover remover (Use with

J–38584)

J–38584

Slide hammer adapter

(Use with J–23907)

J–38554

Fourth clutch piston fitter

ILLUSTRATION TOOL NO.

TOOL NAME

J–38588

Guide pins; adapter case

to main case

J–38555

Overrun clutch piston

seal installer set

J–3387–2

Guide pins; gasket and

transfer plate to valve

body

J–25022

Turbine shaft puller (Use

with J–24773–1)

J–23129

Oil seal remover (Use

with J–23907 and J–

38584)

J–38557

Oil pump centering tool

ILLUSTRATION TOOL NO.

TOOL NAME

J–23082–01

Oil pump rotation tool

J–25025–B

Guide pins; valve body to

main ca se

J–38428

Servo piston fitter

J–23327–91

Overrun clutch spring

compressor

J–38559–A

3/4 accumulator piston

cover compressor

J–8763–02

Holding fixture

ILLUSTRATION TOOL NO.

TOOL NAME

J–36797

A/T extension housing oil

seal installer (Insi de)

J–3289–20

Holding fixture base

J–29770–A

Pressure gauge

J–24773–1

End play fixture (Use with

J–25022)

J–23907

Slide hammer

ILLUSTRATION TOOL NO.

TOOL NAME

4L30–E PARTS LIST

Case and Associated Parts

241RY00001

Legend

(1) Torque Converter

(2) Screw, Seal Ring Assembly

(3) Seal Ring Assembly, Converter Housing

(4) Screw, Converter Housing/Main Case

(5) Screw, Converter Housing/Oil Pump

(6) Housing, Converter

(7) Plug, Converter Housing

(8) Seal, O-ring

(9) Wear Plate, Oil Pump Body

(10) Pump Assembly, Oil

(11) Gasket

(12) Washer, Thrust Selective

(13) Ring, Snap

(14) Cover, 3–4 Accumulator Piston

(15) Seal, O-ring, 3–4 Accumulator

(16) Spring, 3–4 Accumulator Piston

(17) Pin, 3–4 Accumulator Piston

(18) Piston, 3–4 Accumulator

(19) Ring, 3–4, Accumulator Piston

(20) Case, Adapter

(22) Connector, Electrical/Adapter Case

(23) Screw, Pan

(27) Restrictor, Oil

(28) Gasket, Transfer Plate/Adapter

(29) P la te, Transfer Adapte r/Center Support

(30) Support Assembly, Center

(31) Screw, Center Support

(32) Ring, Oil Seal

(33) Seal, O-ring Main Case

(34) Fitting, Cooler

(35) Fitting Assembly, Cooler

EndOFCallout

(36) Case, Main

(37) Br eat her, Pipe

(38 ) Seal, O-ring

(39) Reservoir

(42) Ga sk et, Exten si on Cas e

(43) Extension Assembly

(44) Seal, O-ring/Speed Sensor

(45 ) Sensor Assembly, Speed

(46) Sc rew, Speed Senso r

(50) Seal, Extension Assembly

(51) Bearing, Needle/Extension

(52) Sc rew, Extension/M ai n Case

(53) Spring, Parking Pawl Lock

(54) Pawl, Parking Lock

(55) Connector, Electrical/Main Case

(56) Actuator Assembly, Parking Lock

(57) Nut, Parking Lock Lever

(58) Link, Manual Valve

(59) Pin, Spring

(60) Lever, Parking Lock and Range Selector

(61) Shaft, Selector

(62) Seal, Selector Shaft

(63) Mode Switch Assembly

(64) Screw & Conical Washer Assembly

(65) Shield, Mode Switch

(67) Pan, Bottom/Adapter Case

(68) Gasket, Bottom Pan/Adapter Case

(69) Harness Assembly, Adapter Case

(70) Screw, Val v e Bod y

(71) Valve Body Assembly, Adapter Case

(72) Gasket, Adapter Valve Body

(73) Plate, Adapter Valve Body/Transfer

(74) Pan, Bottom/Main Case

(75) Gasket, Bottom Pan/Main Case

(76) Gasket, Oil Drain or Overfill Screw

(77) Screw, Oil Drain or Overfill

(78) Magnet, Chip Collector

(79) Fi lter Oil

(80) Harness Assembly, Main Case

(82) Roller and Spring Assembly, Manual Detent

(84) Valve Body Asse mbl y, Main Case

(85) Ball, Check

(86) Gasket, Main V.B./Transfer Plate

(87) Plate, Main V.B./Transfer

(88) Gasket, Transfer/Main Case

(89) S cre w, Tran sfer Plate on V.B .

(90) Screw, Servo Cover

(91) Cover, Servo Piston

(92) Gasket, Cover/Servo Piston

(93) Ring, Retaining Servo Piston

(94) Clip, Servo Piston

(95) Nut, Servo Screw

(96) Screw, Servo Piston

(97) Piston, Servo

(98) Seal, Ring/Servo Piston

(99) Spring, Cushion/Servo Piston

(100) Seat, Cushion Spring

(101) Sleeve, Servo Piston Adjust

(102) Rod, Apply/Servo Pis ton

(103) Spring, Return/Servo Piston

(104) Gasket, Adapter Case/Transfer Plate

(105) Powertrain Control Module

(106) Servo Piston Assembly

Pump Assembly

241RS019

EndOFCallout

Legend

(201) Gear, Oil Pump Drive

(202) Gear, Oil Pump Driven

(203) Pin, Boost Valve Sleeve

(204) Sleeve, Boost Valve

(205) Valve, Boost

(206) Seat, Spring/Pressure Regulator Valve

(207) Spring, Pressure Regulator Valve

(208) Valve, Pressure Regulator

(209) Pump Assembly, Oil

(210) Valve, Converter Clutch Control

(211) Spring, Converter Clutch Control Valve

(212) Plug, Converter Clutch Control Valve

(213) Pin, Spring

(214) Piston, Throttle Signal Accumulator

(215) Spring, Throttle Signal Accumulator

(216) Seat, Spring/Throttle Signal Accumulator

(217) Ring, Snap/Throttle Signal Accumulator

Valve Bo dy Assemblies

244RS009

EndOFCallout

Legend

(301) Body, Valve Main Case

(302) Pin, Spring

(303) Solenoid Assembly, ON/OFF N.C.

(304) Valve, 1–2 & 3–4 Shift

(305) Spring, 1–2 & 3–4 (2–3) Shift

(306) Retainer, Valve

(307) Solenoid Assembly, ON/OFF N.O.

(308) Valve, 2–3 Shift

(309) Pin, Spring

(310 ) Plug, Valve Bore

(311) S prin g, Valve Low Pr es su re Contro l

(312) Valve, Low Pressure Control

(317) Ball, Check

(318) Valve, 1–2 Accumulator Control

(320) Valve, 1–2 Accumulator

(321) Washer, Waved PWM Solenoid

(322) Pin, Solenoid PWM

(323) S ol eno id As se mbl y, Band Contr ol PWM

(324) Screen Assembly, PWM Solenoid

(325) Plug, Screen

(326) Valve, Manual

243R100002

EndOFCallout

Legend

(401) Body, Valve/Adapter Case

(402) Screw, Pressure Control Solenoid

(403) Retainer, Pressure Control Solenoid

(404) Solenoid, Pressure Control

(405) Plug, 3–4 Accumulator

(406) Plug and Spring Retainer

(407) Valve, 3–4 Accumulator

(409) Valve, 3–4 Accumulator Control

(410) Spring, Feed Limit Valve

(411) Ring, Retainer

(412) Valve, Feed Limit

(413) Seal, O-ring Plug Filter

(414) Plug, Screen

(415) Screen Assembly, Pressure Control Solenoid

(416) Solenoid, Torque Conv. Clutch ON/OFF N.C.

(417) Plug Retainer

Overdrive Internal Components

252RW003

EndOFCallout

Legend

(501) Retainer, 4th Clutch

(502) Pl ate, 4th Clut ch (Steel)

(503) P l ate As se mbl y, 4th Clutch (Lin ed)

(504) Retainer and Ball Assembly, Check Valve

(505) Seal, O-ring/Turbine Shaft

(506) Shaft, Turbine

(508) Ring, Oil Seal/Turbine Shaft

(510) Housing, Overrun Clutch

(513) Piston, Overrun Clutch

(514) Spring, Overrun Clutch Release

(515) Retainer, Release Spring/Overrun Clutch

(516) Roller Assembly, Overdrive Clutch

(517) Cam, Overdrive Roller Clutch

(518) Ring, Snap/Overrun Clutch Hub

(519) Gear, Overdrive Sun

(520) Plate, Waved/Overrun Clutch

(521) Plate, Overrun Clutch (Steel)

(522) Plate Assembly, Overrun Clutch (Lined)

(523) Plate, Backing/Overrun Clutch

(524) Ring, Snap/Overrun Clutch Housing

(525) Carrier Assembly, Overdrive Complete

(526 ) Rin g, Snap/Turbine Shaft/Carrier

(527) Bearing Assembly, Thrust

(528) Gear, Overdrive Internal

(529) Washer, Thrust/Internal Gear/Support

(530) Ring, Snap/Adapter/4th Clutch Spring

(531) Retainer and spring assembly, 4th clutch

(532) Piston, 4th Clutch

(533) Seal, 4th Clutch Piston (Inner)

(534) Seal, 4th Clutch Piston (outer)

Internal Component s

247RW002

Legend

(608) Seal, Reverse Clutch Piston (Inner)

(609) Seal, Reverse Clutch Piston (Outer)

(610) Piston, Reverse Clutch

(611) Spring, Piston Clutch

(612) Seat, Spring/Reverse Clutch

(613) Ring, Retaining

(614) Plate, Waved/Reverse Clutch

(615) Plate, Reverse Clutch (Steel)

(616) Plate Assembly, Reverse Clutch (Lined)

(617) Plate, Reverse Clutch Pressure/Selective

(618) Drum Assembly, 2nd Clutch

(620) Seal, 2nd Clutch Piston (Inner)

(621) Seal, 2nd Clutch Piston (Outer)

(622) Piston, 2nd Clutch

(623) Seat, Spr ing/2nd Clutch

(625) Pl ate, Waved/2nd Clutch

(626) Plate, 2nd Clutch (Steel)

(627) Plate Assembly, 2nd Clutch (Lined)

(628) Spacer, 2nd Clutch

(629) Ring, Retaining

(630) Gear, Ring

(631) Washer, Thrust/2nd Clutch/3rd Clutch

(632) Thrust Washer, Clutch Hub

(634) Drum Assembly, 3rd Clutch

(635) Seal, 3rd clutch piston (Inner)

(636) Washer, Retaining

(637) Seal, 3rd Clutch Piston (Outer)

(638) Piston 3rd Clutch

(639) Seat, Spring/3rd Clutch

(640) Ring, Retaining

(641) Plate, Spring Cushion/3rd Clutch

(642) Plate, 3rd Clutch (Steel)

(643) Plate Assembly, 3rd Clut ch (Lined)

(644) Washer, Thrust/Input Sun

(645) Bearing, Input Shaft/Gear Assembly

EndOFCallout

Center Support Assembly

242RY002

EndOFCallout

(646) Gear Assembly, Input Sun

(647) Race Assembly, Sprag

(648) Ring, Retaining/Sprag

(649) Ring, Retaining

(650) Cage Assembly, Sprag

(651) Bearing, Output Shaft/Input Sun

(652) Washer, Output Shaft/Input Sun

(653) Carrier Assembly, Planetary

(658) Gear, Reaction Sun

(659) Drum, Reaction Sun

(664) Band Assembly, Brake

(667) Seal, Ring/Wheel Parking Lock

(668) Wheel, Pa rkin g Lo ck

(672) W he el, Sp eed

(673) Ring, Retaining

(675) B ear i ng, Thr us t Assemb ly

Legend

(701) Center Sup port

(702) Retainer Plate

(703) Plug, Lockout

(704) Spring, Lockout

(705) Valve, Overrun Lockout

(706) Valve, Reverse Lockout Control