SECTION 7A - AUTOMATIC TRANSMISSION (4L30–E)

Service Precaution

Construction

Range Reference Chart

Normal Operation of 2000 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

(Adapter 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

Disassemble

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:IF SO EQUIPPED WITH 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.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU 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

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 Assembly (One W ay Clutch)

(PFW)

Range Reference Chart

C07RT010

Normal Operation of 2000 4L30–E

Transmission

Torque Converter Clutch (TCC)

Application Conditions:

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

(158°F).

— The brake pedal is released.

— The shift pattern requests TCC apply.

Moreover, TCC is always applied in 2nd, 3rd and 4th

gears when the transmission oil temperature is above

135°C (275°F).

This mode should be canceled at 125°C (257°F).

ATF Warning Lamp

The A TF warning lamp will be constantly on (not flashing)

if the transmission oil temperature is above 145°C

(293°F).

The ATF warning lamp goes off again when the

transmission oil temperature is below 125°C (257°F).

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 analyze the problem fill out a complete description of

the owner’s complaint.

Please draw a circle around the right information and

complete the following form. (The next page is an

example of a completed form.)You can draw a circle

around many numbers if you are not sure.

F07RT036

Example of form completed.

F07RT037

General Diagnosis Procedure

F07RT038

Preliminary Inspection Chart

F07RY00001

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 Maintenance and Lubrication in General

Information section for maintenance information and

servicing interval.

CAUTION:DO NOT OVERFILL.

Overfilling will cause foaming, loss of fluid, abnor-

mal shifting and possible damage to the transmis-

sion.

1.Park the vehicle on level ground and apply the parking

brake firmly.

2.Check fluid level with engine running at idle.

NOTE:Be sure that transmission fluid temperature is

below 30°C (86°F).

3.Move the selector lever through all gear ranges.

4.Move the selector lever to “Park”.

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

screw (1).

6.Add released transmission fluid until it flows out over

the overfill screw opening.

7.Let engine idle until a fluid temperature between 32°C

(90°F) and 57°C (135°F) is reached, then close the

overfill screw (1).

Torque: 38N•m(28lbft)

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.Minimum fluid level → 57°C (135°F)

Maximum fluid level → 32°C (90°F)

242RW003

CAUTION:Do not open overfill screw with engine

stopped.

CAUTION:DO NOT CHECK FLUID LEVEL UNDER

THESE CONDITIONS:

DImmediately after driving at sustained highway

speeds.

DIn heavy city traffic during hot weather.

DIf 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.

Techline

Fluid Condition

FLUID CONDITION

NORMAL* CONTAMINATED

COLOR RED OR LIGHT

BROWN BROWN NON–TRANSPARENT

/ PINK BROWN

DRAIN

REQUIRED? NO YES YES YES

CONTAMI-

NATION 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:

A.Add fluid to

obtain proper

level & check for

external leaks.

B.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

–Transmission

overhaul required

–Check for:

DDamaged plates

and seals

DContaminated

solenoids

–Flush cooler

–Add new fluid

–Check level

–Transmission

overhaul required

–Flush cooler and

cooler lines

–Add new fluid

–Check level

*Fluid should be changed according to maintenance

schedule.

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) trouble code. Perform this procedure

before each 4L30–E automatic transmission repair, and

again after repairs are made.

IMPORTANT:

DDuplicate the condition under which the customer’s

complaint was observed.

DDepending on the complaint, the line pressure gauge

and the scan tool may be required during the test

drive.

DDuring 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.

DIf the lamp is flashing, GOTO Check Trans Indicator

in Transmission Control System (4L30–E) section.

DIf no serial data is present, GOTO OBD System

Check. Refer to Driveability and Emissions in

Engine section.

DIf the lamp stays ON or stays OFF, GOTO “Check

Trans” Check in Transmission Control System

(4L30–E) section.

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

trouble codes are present, drive the vehicle with the

PCM disconnected (manually shifting the vehicle).

DIn Manual L, the vehicle operates in first gear.

DIn Manual 2, the vehicle operates in third gear.

DIn Manual 3 or “D”, the vehicle operates in fourth

gear.

If the problem still exists with the PCM disconnected,

refer to Mechanical/Hydraulic Diagnosis in this

section.

5.If no problem has been found at this point, check all

underhood connections that supply power to the PCM

and ignition fuses. Physically and visually inspect all

the PCM harness connectors for loose 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 system is now operating in a “BACKUP MODE”

where the risk of further damaging the transmission has

been 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 reoccurs.

F07RT013

Mechanical / Hydraulic Diagnosis Symptoms Index

Perform Preliminary Inspection First!

CHART SYMPTOMS

1NO ENGINE START IN NEUTRAL OR PARK

2NO FORWARD GEARS IN ANY RANGE/NO REVERSE

3NO ENGINE BRAKE IN ANY RANGE

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

5a DELAYS IN DRIVE AND REVERSE

5b DELAYS IN REVERSE ONLY

6DIAGNOSTIC TROUBLE CODE (DTC) P0730

7HARSH 1–2 SHIFT

8HARSH 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 TRANSMISSION NOISE

15a POSSIBLE CAUSES OF LOW LINE PRESSURE

15b POSSIBLE CAUSES OF HIGH LINE PRESSURE

16 POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS

NOTE:Numbers with parenthesis on the following charts

refer to Parts List at end of this section.

Chart 1: No Engine Start In Neutral Or Park

Step Action Yes No

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

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

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

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

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

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

Problems fixed? Re–test vehicle Go to Step 5

5Check 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

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15a:

Possible Causes

of Low Line

Pressure in this

section.

21. Check internal linkage:

– 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 —

Chart 3: No Engine Brake In Any Range

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15a:

Possible Causes

of Low Line

Pressure in this

section.

21. 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)

Step Action Yes No

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

Was line pressure normal? Go to Step 2 Go to Step 3

21. Check for these conditions which could affect clutch apply

time:

– Defective band apply solenoid (323).

– Defective servo or/and accumulator piston.

– Excessive clutch piston travel.

2. Check of possible causes of internal leaks:

– Cut or damaged sealing ring(s)

– Damaged sealing gasket(s)

– Check ball missing 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 —

3Was the line pressure high?

Go to Step 4

Use Chart 15a:

Possible Causes

of Low Line

Pressure in this

section.

4Were DTCs P0560 and P0705 set?

Diagnose those

DTC(s) first.

Use Chart 15b:

Possible Causes

of High Line

Pressure in this

section.

Chart 5a: Delays In Drive and Reverse

NOTE: A short delay (less than 3 seconds) when first

engaging drive or reverse after allowing vehicle to sit

overnight is normal.

Step Action Yes No

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

Was 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

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

Was line pressure normal?

Go to Step 2

Use Chart 15a:

Possible Causes

of Low Line

Pressure in this

section.

2Main 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

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

Was line pressure normal?

Go to Step 2

Use Chart 15b:

Possible Causes

of High Line

Pressure in this

section.

21. 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 clutch piston travel.

– Defective 3–4 accumulator piston.

– Causes of internal leaks.

– Causes of burned clutch plates.

Was the problem found? Repair or replace —

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

Does vehicle move? Shift solenoid A

stuck. Replace

shift solenoid A. Go to Step 4

4Check 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

Step Action Yes No

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

Was 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 Line

Pressure in this

section.

Chart 8: Harsh 3–4 Shift

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15b:

Possible Causes

of High Line

Pressure in this

section.

21. Check for 3–4 accumulator valve (407) stuck in adapter case

valve body (401).

2. Check for 3–4 accumulator piston (18) stuck in adapter case

(20).

Was the problem found? Repair or replace —

Chart 9a: 3–2 Downshift Complaint

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15a:

Possible Causes

of Low Line

Pressure in this

section.

2Does DTC P1850 set? Diagnose P1850

first.

Replace band

apply solenoid

(PWM) (323).

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

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15b:

Possible Causes

of High Line

Pressure in this

section.

2Does DTC P1850 set? Diagnose P1850

first.

Replace band

apply solenoid

(PWM) (323).

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

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15b:

Possible Causes

of High Line

Pressure in this

section.

2Does DTC P1850 set? Diagnose P1850

first.

Replace band

apply solenoid

(PWM) (323).

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

Step Action Yes No

1Check for consistent speed sensor reading with scan tool.

Was the reading correct? Replace mode

switch for

intermittent

contact. Go to Step 2

21. 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.

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

Step Action Yes No

1Check for oil leaks at transmission.

Was the problem found? Replace

transmission oil

filter and gasket. —

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

Step Action Yes No

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

Was line pressure normal?

Go to Step 2

Use Chart 15a:

Possible Causes

of Low Line

Pressure in this

section.

21. 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

Step Action YesNo

11.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

what conditions. Once the TCC has been fully applied, 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.From coast condition at 50 mph in “D” range (Normal mode),

depress the throttle to 1/4-1/3 throttle. If present, shudder will

occur within 5 seconds together with TCC application.(The

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

Was the problem found?

Replace

transmission fluid

and filter (remove

both pans) and

flush cooler lines.

Replace

converter

assembly and

O-ring on turbine

shaft

Perform

mechanical

inspection of

other drivetrain

components.

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 components.

Condition Possible cause Correction

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.

ransm

on. Cracked or broken flex plate Replace flex plate.

Converter damaged Replace converter.

Knocking noise while driving, mostly

on acceleration. T ransmission 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.

onary. Cracked or broken flex plate Replace flex plate.

Damaged converter Replace converter.

Chart 15a: Possible Causes of Low Line Pressure

Step Action Yes No

1Check oil level.

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

2Check for defective throttle position sensor.

Was the problem found? Replace throttle

position sensor. Go to Step 3

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

Was the problem found? Inspect oil filter,

tighten bolts or

replace oil filter

(79). Go to Step 4

4Check for a stuck force motor plunger (404). (Adapter case valve

body)

Was the problem found?

Replace force

motor plunger

(404). Go to Step 5

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

Was the problem found? Replace feed limit

valve (412). Go to Step 6

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

Was the problem found? Tighten converter

bolts (4 & 5). Go to Step 7

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

Was the problem found? Replace pressure

regulator valve

(208). Go to Step 8

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

Was the problem found? Replace boost

valve (205). Go to Step 9

9Check 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.

Step Action Yes No

1Check for defective throttle position sensor.

Was the problem found? Replace throttle

position sensor. Go to Step 2

2Check for a stuck force motor plunger (404). (Open

circuit/intermittent) (Adapter case valve body)

Was the problem found?

Replace force

motor plunger

(404). Go to Step 3

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

Was the problem found? Replace feed limit

valve (412). Go to Step 4

4Check converter bolts (4 & 5).

Was the problem found? Tighten converter

bolts (4 & 5). Go to Step 5

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

Was the problem found? Replace pressure

regulator valve

(208). Go to Step 6

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

Was the problem found? Replace boost

valve (205). Go to Step 7

7Check 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. —

Chart 16: Possible Causes of

Transmission Fluid Leaks

Before attempting to correct an oil leak, the actual source

of the leak must be determined. In many cases, the

source 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 in-

specting for the source of the leak.

Oil leaks around the engine and transmission are gener-

ally carried toward the rear of the vehicle by the air

stream. In determining the source of an oil leak, the fol-

lowing 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.

Possible Causes of Fluid Leaks Due To Sealing Malfunction

240RX008

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)

Stall Test

The stall test allows you to check the transmission for

internal abrasion and 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.

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 : 2,200 ±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.Remove the pressure detection plug at the left side of

the transmission case.

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

pressure detection plug hole.

241RS001

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.

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 accelerator

pedal fully depressed.

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.Install a pressure detection plug to the transmission

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 pressure detection plug to the specified

torque.

Torque: 9 – 14N·m (7 – 10lb ft)

MODE

LEVER

ENGINE SPEED

LINE PRESSURE FORCE MOTOR

MODE

POSITION

ENGINE

SPEED

kPa PSI CURRENT

NORMAL/POWER D,3,2,L IDLE 312–363 45.2–52.6 VARIABLE

WINTER D IDLE 312 – 363 45.2 – 52.6 0.9 – 1.0A

NORMAL/POWER

WINTER REVERSE IDLE 419 – 486 60.7 – 70.5 0.9 – 1.0A

NORMAL/POWER D, 3, 2, L STALL SPEED 1,236 – 1320 179.3 – 191.4 0.1 – 0.2A

WINTER DSTALL SPEED 1,236 – 1320 179.3 – 191.4 0.1 – 0.2A

NORMAL/POWER

WINTER REVERSE STALL SPEED 1,634 – 1743 236.9 – 252.8 0.1 – 0.2A

Shift Speed Chart

Transfer gear ratio High: 1.000

Rear axle ratio 4.100

“Normal mode”

Upshift

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)

DFully opened 52 ∼ 58 (33 ∼ 36) 105 ∼ 111 (66 ∼ 69) 158 ∼ 164 (99 ∼ 102)

(Drive) Half throttle 33 ∼ 39 (21 ∼ 24) 60 ∼ 66 (37 ∼ 41) 100 ∼ 106 (62 ∼ 66)

3Fully opened 52 ∼ 58 (33 ∼ 36) 105 ∼ 111 (66 ∼ 69) —

(Third) Half throttle 33 ∼ 39 (21 ∼ 24) 60 ∼ 66 (37 ∼ 41) —

2Fully opened 52 ∼ 58 (33 ∼ 36) — —

(Second) Half throttle 33 ∼ 39 (21 ∼ 24) — —

Downshift

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)

Fully opened 42 ∼ 48 (26 ∼ 30) 93 ∼ 99 (58 ∼ 62) 149 ∼ 155 (93 ∼ 97)

(Drive)

Half throttle 16 ∼ 22 (10 ∼ 14) 35 ∼ 42 (22 ∼ 26) 70 ∼ 76 (43 ∼ 47)

(Drive)

Fully closed 13 ∼ 20 (8 ∼ 12) 16 ∼ 22 (10 ∼ 14) 28 ∼ 34 (17 ∼ 21)

Fully opened 42 ∼ 48 (26 ∼ 30) 93 ∼ 99 (58 ∼ 62) —

(Third)

Half throttle 16 ∼ 22 (10 ∼ 14) 35 ∼ 42 (22 ∼ 26) —

(Third)

Fully closed 13 ∼ 20 (8 ∼ 12) 16 ∼ 22 (10 ∼ 14) —

Fully opened 43 ∼ 49 (27 ∼ 31) 101 ∼ 107 (63 ∼ 67) —

(Second)

Half throttle 16 ∼ 22 (9 ∼ 13) 98 ∼ 104 (61 ∼ 65) —

(Second)

Fully closed 13 ∼ 20 (8 ∼ 12) 85 ∼ 91 (53 ∼ 57) —

(First) — 53 ∼ 59 (33 ∼ 37) — —

“Power mode”

Upshift

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)

DFully opened 52 ∼ 58 (33 ∼ 36) 105 ∼ 111 (66 ∼ 69) 180 ∼ 186 (113 ∼ 116)

(Drive) Half throttle 38 ∼ 45 (24 ∼ 28) 77 ∼ 83 (48 ∼ 52) 129 ∼ 133 (80 ∼ 84)

3Fully opened 52 ∼ 58 (33 ∼ 36) 105 ∼ 111 (66 ∼ 69) —

(Third) Half throttle 38 ∼ 45 (24 ∼ 28) 77 ∼ 83 (48 ∼ 52) —

2Fully opened 52 ∼ 58 (33 ∼ 36) — —

(Second) Half throttle 38 ∼ 45 (24 ∼ 28) — —

Downshift

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)

Fully opened 43 ∼ 49 (27 ∼ 31) 96 ∼ 102 (60 ∼ 64) 170 ∼ 176 (106 ∼ 110)

(Drive)

Half throttle 22 ∼ 28 (14 ∼ 17) 55 ∼ 61 (34 ∼ 38) 102 ∼ 108 (63 ∼ 67)

(Drive)

Fully closed 13 ∼ 20 (8 ∼ 12) 25 ∼ 31 (16 ∼ 19) 48 ∼ 54 (30 ∼ 33)

Fully opened 43 ∼ 49 (27 ∼ 31) 96 ∼ 102 (60 ∼ 64) —

(Third)

Half throttle 22 ∼ 28 (14 ∼ 17) 55 ∼ 61 (34 ∼ 38) —

(Third)

Fully closed 13 ∼ 20 (8 ∼ 12) 25 ∼ 31 (16 ∼ 19) —

Fully opened 43 ∼ 49 (27 ∼ 31) 101 ∼ 107 (63 ∼ 67) —

(Second)

Half throttle 22 ∼ 28 (14 ∼ 17) 98 ∼ 104 (61 ∼ 65) —

(Second)

Fully closed 13 ∼ 20 (8 ∼ 12) 85 ∼ 91 (53 ∼ 57) —

(First) — 53 ∼ 59 (33 ∼ 37) — —

“Winter mode”

D range, winter mode ON → OFF 32 ∼ 38 km/h (20 ∼ 24 mph)

Lockup Speed Chart

Transfer gear ratio High: 1.000

Rear axle ratio 4.100

Lockup ON Lockup OFF

D range,

Throttle o

ening

Mode 2nd

km/h

(mph)

3rd

km/h

(mph)

4th

km/h

(mph)

2nd

km/h

(mph)

3rd

km/h

(mph)

4th

km/h

(mph)

Throttle

o ening

6% Normal 79 ∼ 85

(49 ∼ 53) 58 ∼ 64

(36 ∼ 40) 69 ∼ 75

(43 ∼ 47) 74 ∼ 80

(46 ∼ 50) 49 ∼ 55

(30 ∼ 34) 65 ∼ 71

(40 ∼ 44)

Power 79 ∼ 85

(49 ∼ 53) 84 ∼ 90

(52 ∼ 56) 84 ∼ 90

(52 ∼ 56) 74 ∼ 80

(46 ∼ 50) 76 ∼ 82

(47 ∼ 51) 81 ∼ 87

(50 ∼ 54)

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 (28lbft)

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

(90°F) and 57°C (135°F) is reached.

6.Add transmission fluid until it flows out over the overfill

screw opening, then close the overfill screw (1).

Torque: 38N•m (28lbft)

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 OBD II Connection in Transmission

Control System (4L30-E) section.

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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.Check to see if the selector lever can be shifted as

shown in illustration.

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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.

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5.Remove rear console.

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6.Remove center console.

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7.Remove selector lever knob and cover.

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8.Disconnect select cable.

DRefer to Select Cable in this section.

9.Disconnect shift lock cable.

DRefer to Shift Lock Cable in this section.

10.Disconnect harness connector.

11.Remove selector lever subassembly.

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Installation

1.Install selector lever subassembly.

2.Connect harness connector.

3.Connect shift lock cable.

DRefer to Shift Lock Cable in this section.

4.Connect select cable.

DRefer to Select Cable in this section.

5.Install selector lever knob and cover.

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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.

DRefer to Selector Lever in this section.

3.Disconnect inner cable by pulling projection on pin.

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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.Disconnect inner cable.

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7.Pull lock.

A07RW015

8.Slide sleeve and disconnect cable assembly.

A07RW082

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 .

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

selector lever hole and inner cable end.

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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.

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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.

DRefer to Selector Lever in this section.

3.Disconnect inner cable from selector lever assembly

then push claw and disconnect cable assembly.

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4.Disconnect lock adjust.

256RW017

5.Remove instrument panel lower cover and steering

column cover.

6.Remove spring pin and disconnect inner cable.

DDisconnect outer cable from bracket.

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Installation

1.Set ignition key in “LOCK” position and selector lever

in “P” position.

2.Connect outer cable to bracket near steering lock.

DConnect 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.

DInstall inner cable to lever, pulling inner cable with

outer cable.

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5.Check that cable moves smoothly, lightly pulling outer

cable rearward.

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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 shift lock operation:

a. Selector lever should not be moved out of “P”

position with ignition key in “Lock” position.

b. Selector lever can be moved 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).

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Installation

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

noting the following points;

1.Torque

Mode switch bolt: 13 N•m (113 lb in)

Selector lever nut: 23 N•m (17 lb ft)

2.Mode switch setting procedure

Perform either of the following adjustment

procedures:

Procedure 1

a. Place selector 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 3/32 in. (2.4 mm) drill bit or

punch (1) into the slot.

f. Tighten the screws to 13 N·m (113 lb in).

g. After completing adjustment, snap the mode

switch cover into place.

h. Reinstall the selector lever.

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Procedure 2

a. Place selector lever in neutral.

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 switch slightly in both directions 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

switch connector.

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Transmission (With Transfer Case)

Transmission and Associated Parts

240RX012

Legend

(1) Skid Plate

(2) Transfer Protector

(3) Rear Propeller Shaft

(4) Front Propeller Shaft

(5) Center Exhaust Pipe

(6) Harness Heat Protector

(7) Rear Mount Nut

(8) Third Crossmember

(9) Transmission Oil Cooler Pipe

(10) Starter

(11) Under Cover

(12) Transfer Control Lever

(13) Select Cable

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

(15) Engine-Transmission Bolt

(16) Transmission Assembly (With Transfer Case)

Removal

NOTE: 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.

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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 removal of the fuel hose connector is required for

transmission servicing and/or replacement, follow the

steps below.

NOTE:

DAn 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 procedure. Do not allow

the serfaces to become contaminated with dirt or

other foreign material.

DPerform 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 togeth-

er , jiggle the connector back 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 connector into the fuel pipe until a

distinct click is heard.

141RY00005

3. Gently pull on the connector to check that it is

securely latched.

141RY00006

6.Disconnect transmission harness connector and clip.

Connector : Adapter case, mode switch, main case,

magnetic sensor, transfer switch, 2–4 actuator and

car speed sensor.

7.Remove harness heat protector.

815RW002

8.Support transmission with a jack.

Remove rear mount nuts from the third

crossmember.

F07RW008

9.Remove third crossmember.

10.Disconnect transmission oil cooler pipes from A/T

side.

11.Remove oil pipe clamp and bracket from the

converter housing.

253RX002

12.Remove skid plate and loosen oil cooler pipe clamp

bolt at the engine mount side.

13. Remove select cable by disconnecting inner cable

from select lever and removing outer cable with

bracket.

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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

transmission is aligned with rear of the engine. Join

the transmission to the engine.

2. Tighten engine-transmission bolts as shown in the

figure.

F07RY001

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: 54 N•m (40 lb ft)

NOTE: Do not reuse the flex plate torque converter bolt.

240RX010

4.Install transfer control lever on the transfer case.

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5.Install under covers to the transmission and engine.

Torque: 8 N•m (69 lb in)

6.Install starter.

Torque: 40 N•m (30 lb ft)

7.Install select cable by connecting inner cable to select

lever and installing outer cable with bracket.

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8.Connect transmission oil cooler pipes to A/T.

Torque: 44 N•m (33 lb ft)

9.Install oil cooler pipe clamp and bracket to the

converter housing.

253RX002

10.Tighten oil cooler pipe clamp bolt at the engine mount

side and install skid plate.

11.Install third crossmember.

Torque: 76 N•m (56 lb ft)

12.Install rear mount nuts.

Torque: 50 N•m (37 lb ft)

F07RW008

13.Install harness heat protector.

Torque: 6 N•m (52 lb in)

815RW002

14.Connect transmission harness connector and clip.

Connector : Adapter case, mode switch, main case,

magnetic sensor, transfer switch, 2–4 actuator and

car 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: 43 N•m (32 lb ft)

18.Install transfer protector.

150RX008

19.Install front propeller shaft and rear propeller shaft.

Torque: 63 N•m (46 lb ft)

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.

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8.Remove shift solenoid A, shift solenoid B, 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, 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.

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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 (15lbft)

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 (96lbin)

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 force motor 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.

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7.Remove 11 mm bolt, retainer, and force motor

solenoid.

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Installation

1.Install force motor solenoid, retainer, and 11 mm bolt

to adapter case valve body. Tighten the bolt to the

specified torque.

Torque: 10 N•m (87lbin)

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 (87lbin)

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.

DDisconnect ground wire from the main case valve

body.

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.

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2.Inspect electrical 4 pin connector and seal of main

case. Replace if necessary.

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

DInstall 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: 20 N•m (15 lb ft)

243RS008

5. Install 8.5 mm connector of ground wire under the

head of this valve body bolt and reinstall it. Tighten the

bolt to the specified torque.

Torque: 20 N•m (15 lb ft)

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6.Remove two guide pins from main case.

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

screws. Tighten the screws to the specified torque.

Torque: 25 N•m (18 lb ft)

8.Connect wiring harness to band control and shift

solenoids.

9.Install roller and spring assembly to manual detent.

DInstall two 13 mm screws, and tighten them to the

specified torque.

Torque: 20 N•m (15 lb ft)

10.Install oil filter and three 13 mm screws. Tighten to the

specified torque.

Torque : 20N•m (15lbft)

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

mm screws. Tighten the screws to the specified

torque.

Torque: 11N•m (96lbin)

12.Fill transmission through overfill screw hole of oil pan,

using ATF DEXRON–III. Refer to Changing

Transmission Fluid in this section.

13.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 force motor 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 5 pin 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 (15lbft)

4.Connect wiring harness assembly to converter clutch

solenoid and force motor.

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

screws. Tighten the screws to the specified torque.

Torque: 11N•m (96lbin)

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.Remove transfer control lever knob, lower cluster

assembly, center console and rear console.

3.Disconnect PCM wiring harness connectors from

PCM.

4.Remove four PCM retaining screws.

5.Remove two brackets from PCM.

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Installation

1.Install two brackets to PCM.

2.Install four PCM retaining screws.

3.Connect PCM wiring harness connectors to PCM.

4.Install center console, rear console, lower cluster

assembly and transfer control lever knob.

5.Connect battery ground cable.

Speed Sensor (Extension Housing)

Removal

1.Disconnect battery ground cable.

2.Remove front console.

3.Remove selector lever assembly.

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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 (78lbin)

3.Connect speed sensor harness connector to speed

sensor.

4.Install selector lever assembly.

DAdjust shift lock cable.

Refer to Shift Lock Cable in this section.

5.Install front console.

6.Connect battery ground cable.

Transmission Oil Temperature Sensor (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 and drain the fluid

carefully.

5.Disconnect wiring harness from force motor solenoid,

converter clutch solenoid, and 5 pin connector of

adapter case. Pull only on connectors, not on wiring

harness.

6.Disconnect ground wire from converter clutch

solenoid wiring harness connector.

7.Remove wiring harness assembly (transmission oil

temperature sensor).

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Installation

1.Connect ground wire to converter clutch solenoid

wiring harness connector of the wiring harness

assembly.

2.Install wiring harness assembly to converter clutch

solenoid, force motor, and 5 pin connector of adapter

case.

3.Install oil pan gasket, oil pan and twelve 10 mm fixing

screws. Tighten the screws to the specified torque.

Torque: 11N•m (96lbin)

4.Fill transmission through the overfill screw hole of oil

pan, using ATF DEXRON–III.

Refer to Changing Transmission Fluid in this section.

5.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.

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Installation

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

DInstall oil seal ring to converter housing, tighten to

the specified torque.

Torque: 3N•m (26lbin)

2.Install torque converter to converter housing.

3.Install transmission assembly to the vehicle, refer 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:

DWash each part thoroughly, and blow air through each

oil passage and groove to eliminate blockage.

DSeal rings, roll pins, and gaskets should be replaced.

DWhen assembling the components, apply

DEXRON–III Automatic Transmission Fluid (ATF)

to each seal, rotating part, and sliding part.

DDo not dip part facings, such as clutch or brake drive

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).

DDrain fluid from torque converter.

DAttach 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 5 pin 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.

DRemove wiring harness and 5 pin 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.Remove two 13mm manual detent (9) fixing screws,

roller and spring, and manual detent.

10.Disconnect wiring harness assembly (10) from band

apply solenoid, shift solenoids, and main case 4 pin

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 and ground

wire from main case.

DRemove wiring harness assembly (5) from the

adapter case side.

DRemove main valve body assembly (12) with

manual valve link and transfer plate. Note the

position of the link (long end into valve, short end

into range selector lever).

DRemove 4 pin connector.

DRemove gasket transfer plate from main case.

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

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14.Turn transmission to vertical position to drain fluid.

Return back to horizontal position when drained.

DInstall J–23075 servo piston spring compressor

with offset to the rear of case.

DCompress servo piston assembly.

DRemove servo piston retaining ring (14).

DSlowly release servo piston assembly (15).

DRemove tool.

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

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

242RS002

16.Rotate transmission to horizontal position, pan side

down.

DRemove 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.

DLoosen 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.

DRemove seven outer screws.

DRemove converter housing and oil pump assembly

(23).

22.Remove gasket (24).

23.Remove selective thrust washer (25).

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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.Remove adapter case and center support assembly

(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).

DRelease snap ring (36) from groove.

DRemove 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).

DRemove fourth clutch piston assembly (38) from the

adapter case.

DRemove 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).

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47.Rotate case to horizontal position, valve body side

facing up.

DRemove 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.

DInstall 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.Install parking lock and range selector lever (2) and

new 17 mm nut. Tighten the nut to the specified

torque.

Torque: 22 N•m (16 lb ft)

249RS005

5.Rotate main case to vertical position, extension end

facing down.

DInstall brake band assembly (3).

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

6.Install thrust bearing (4).

NOTE: The case bushing acts as a guide for the thrust

bearing.

7.Install brake drum (5).

8.Install reaction sun gear (6).

9.Install needle bearing (7).

10.Inspect planetary carrier assembly (8) for wear and

damage. If necessary replace it.

DMeasure pinion end play clearance with a feeler

gauge.

Clearance: 0.13mm–0.89mm (0.005 in–0.035 in)

If clearance is outside specified value, replace the

planetary carrier assembly.

248RS001

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

NOTE: Use petroleum jelly to hold the thrust bearing in

place.

12.Align planetary pinions. Each pinion 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 double lines which are to be lined up with

the double points on two opposite pinions; the single

lines are to be lined up with the single points on the

other two pinions.

DAfter 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.

248RS002

14.Remove the third clutch (12).

15.Install bearing (11) and washer (10).

NOTE: Use petroleum jelly to hold the washer and

bearing in place.

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16.Carefully align the second clutch plate inner tangs.

DInstall 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.

17.Install third clutch and intermediate shaft assembly

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

18. Install second and third clutch assemblies into the

main case. T wist output shaft and clutch assemblies

to ensure proper fit.

247RS001

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

valve body face.

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

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

21.Install waved clutch plate (18) with center tang facing

valve body side.

247RS002

22.Second clutch end play measurement

1. Install the J–23085–A selective 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. Measure the gap and select appropriate washer

as shown in the chart.

Selective Thrust Washer

Gap: mm(in) Color

1.53 – 1.63 (0.060 – 0.064) Yellow

1.72 – 1.82 (0.068 – 0.072) Red

1.91 – 2.01 (0.075 – 0.079) Black

2.10 – 2.20 (0.083 – 0.087) Natural

2.29 – 2.39 (0.090 – 0.094) Green

2.48 – 2.58 (0.098 – 0.102) Blue

FOLLOWING THE PROCEDURE SHOULD

RESULT IN FINAL END–PLAY FROM 0.36 mm TO

0.79 mm (0.014 in TO 0.031 in)

247RS003

247RS004

23.Inspect fourth clutch piston seals and replace if

necessary.

DLubricate J–38554 fourth clutch piston fitter and

install it on fourth clutch piston (19).

DInstall fourth clutch piston (19) in adapter case (20).

DRemove fitter.

252RS003

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

clutch piston (21).

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

DInstall J–23327 and J–23327–90 fourth clutch

spring compressor.

DSeat snap ring in groove.

DRemove compressor.

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252RS004

26.Install selective washer using petroleum jelly.

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

case/main case seal ring (25).

28.Install J–38588 guide pins.

DInstall adapter case and center support assembly to

main case.

242RS004

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

tangs pointing downwards.

30.Preassemble overdrive internal gear (27) and thrust

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.

31.Install overdrive carrier (30) and internal gear

assembly into adapter case.

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

Steel, Lined, Steel, Steel, Lined, Steel. Steel plates

go in with short tang facing towards valve body

surface.

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

up and positioned towards valve body surface.

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34.Overdrive clutch end play measurement

1. Install the J–23085–A selective washer gauging

tool on the adapter case flange and against 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.

Selective Thrust Washer

Gap: mm(in) Color

1.53 – 1.63 (0.060 – 0.064) Yellow

1.72 – 1.82 (0.068 – 0.072) Red

1.91 – 2.01 (0.075 – 0.079) Black

2.10 – 2.20 (0.083 – 0.087) Natural

2.29 – 2.39 (0.090 – 0.094) Green

2.48 – 2.58 (0.098 – 0.102) Blue

FOLLOWING THE PROCEDURE SHOULD

RESULT IN FINAL END–PLAY FROM 0.1 mm TO

0.8 mm (0.004 in TO 0.03 in)

252RS005

252RS006

35.Install selective washer (32).

NOTE: Use petroleum jelly to hold selective washer in

place.

36.Install gasket (33).

37.Install converter housing and oil pump assembly (34)

to adapter case.

DFit and tighten seven outer 13 mm screws.

Torque: 39 N•m (29 lb ft)

DEnsure free rotation of pump using J–23082–01

pump rotation tool.

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38.Overdrive clutch end play measurement

1. Fit J–25022 and J–24773–1 turbine 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 (0.004 in – 0.031in)

6. Remove axial play checking tool and puller.

NOTE: If end play is not correct, repeat selective washer

selection.

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39.Inspect extension housing oil seal and replace if

necessary, using J–36797 extension housing oil seal

installer.

DRotate transmission to horizontal position, with

valve body side down.

DInspect parking wheel seal ring. Replace if

necessary.

DInstall wheel parking lock assembly (35).

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

NOTE: Use extra long, needle nose pliers.

41. Install gasket onto extension assembly with a thin

coating of oil.

DInstall extension housing assembly (38), and align

parking pawl shaft.

DInstall actuator assembly into extension assembly.

DInstall seven 8 mm hexagon socket head screws.

Torque: 32 N•m (24 lb ft)

42.Inspect speed sensor O-ring. Replace if necessary.

DInstall speed sensor assembly (39) and 10 mm

screw.

Torque: 9 N•m (78 lb in)

241RW009

241RS004

43.Main case end play measurement

1. Attach axial play checking tool on the extension

housing and set indicator to zero on output shaft.

2. Manually push output shaft upwards.

End play: 0.36mm – 0.80mm (0.014 in – 0.031in)

3. Remove axial play checking tool.

4. If end play is not correct, repeat selective washer

selection.

241RS005

44.Inspect servo piston seal ring. Replace if necessary.

DEnsure brake band is correctly positioned. Rotate

output shaft if necessary.

DInstall J–38428 servo piston fitter in servo bore.

DInstall apply rod (40), round end toward band, return

spring (41) and piston assembly (42).

45.Install the J–23075 servo spring compressor with

offset to rear of case.

DCompress servo piston seal ring, using fitter while

tightening the tool screw.

DInstall servo piston retaining ring (43).

DRemove tool.

DAdjust the brake band by tightening the servo

adjusting screw to 4.5 N·m 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.

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46.Install two check balls (44).

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47.Inspect main case electrical connector and seal,

replace if necessary.

DInstall electrical 4 pin connector/main case and

wiring harness.

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

DInstall 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.

DInstall seven 13 mm screws, tighten the specified

torque.

Torque: 20 N•m (15 lb ft)

DPass ground wire of adapter case wiring harness

assembly through the hole joining adapter fluid area

and main case fluid area.

DAssemble 8.5 mm connector of ground wire under

the head of this valve body bolt and reinstall it.

DRemove two guide pins.

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

screws.

Torque: 25 N•m (18 lb ft)

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

solenoids, and main case 4 pin connector.

51.Install manual detent roller and spring assembly (48)

with clip.

DInstall two 13 mm screws.

Torque: 20 N•m (15 lb ft)

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

Torque: 20 N•m (15 lb ft)

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

sixteen 10 mm screws.

Torque: 11 N•m (96 lb in)

54.Inspect adapter case electrical connector and seal.

Replace if necessary.

DInstall electrical five pin connector and harness

assembly (52) in bottom of adapter case.

55.Install gasket, transfer plate, and gasket.

DInstall adapter case valve body (51) complete and

seven 13 mm screws.

Torque: 20 N•m (15 lb ft)

56.Connect wiring harness harness assembly (52) to

converter clutch solenoid, force motor, and 5 pin

connector.

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

twelve 10 mm screws.

Torque: 11N•m (96lbin)

DRotate transmission, with bottom pan facing down.

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

lever nut, and cover.

10 mm screw

Torque: 13N•m (113lbin)

Nut

Torque: 23N•m (17lbft)

DAdjust using setting tool, refer to Mode Switch in

this section.

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

60.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.

DRotate transmission, bell housing up. Spin

converter to insure proper fit.

61.Fill transmission through the overfill screw hole of oil

pan, using ATF DEXRON–III. Refer to Changing

Transmission Fluid in this section.

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Converter Housing and Oil Pump Assembly

Disassembled View

241RW003

Legend

(1) Converter Housing

(2) Outer Seal Ring

(3) Gasket

(4) Wear Plate

(5) Oil Pump Assembly

(6) Oil Seal Ring

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.

DLoosely install five 13mm bolts.

DCenter converter housing using J–38557 centering

tool.

DTighten five inner 13mm bolts in an alternating

pattern.

Torque: 20 N•m (15 lb ft)

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3.Install oil seal ring (3 screws).

Torque: 3 N•m (26 lb in)

4.Install gasket.

5.Install outer seal ring.

Oil Pump

Disassembled View

241RS014

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

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.Install pressure regulator valve (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.Install boost valve and sleeve assembly, and sleeve

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

5.Install throttle signal accumulator piston (10), spring

(9), and spring seat (8), with the 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).

Main Case Valve Body

Disassembled View

244RS010

Legend

(1) Gaskets and Transfer Plate

(2) Manual Valve

(3) Band Control Solenoid

(4) Pin

(5) Waved W asher

(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

Disassembly

1.Remove two 11mm bolts from valve body (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).

8.Remove spring pin (1 1) 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.Install spring (15), 2–3 shift valve (14), retainer (13),

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.Install waved washer (5), band control 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.

DInstall two 11mm bolts.

Torque: 13 N•m (113 lb in)

244RS004

DInstall gasket (transfer plate/main case).

Adapter Case Valve Body

Disassembled View

243RW001

Legend

(1) Converter Clutch Solenoid Assembly

(2) Retainer

(3) Force Motor Solenoid

(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) Force Motor Screen Assembly

(15) Adapter Case Valve Body

Disassembly

1.Remove 11mm bolt from valve body.

DRemove converter control solenoid assembly (1).

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

DRemove force motor 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 (1 1), O-ring (12), plug (13), and

force motor screen assembly (14).

DUse 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.

Reassembly

1.Install force motor 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 force motor solenoid (3).

DPlace solenoid terminals pointing towards mating

face.

DInstall retainer (2) and bolt.

Torque: 10 N•m (87 lb in)

5.Install converter clutch solenoid assembly with two

O-rings (1) to valve body.

DInstall bolt.

Torque: 10 N•m (87 lb in)

Third Clutch and Sprag Unit

Disassembled View

248RW001

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

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 using a small screwdriver instead of

the depressor handle provided with the tool

J-38450-A. Slide one blade down between the 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 blades. 248RX001

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

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

clutch drum assembly (8).

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.

DSimultaneously 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

Legend

(1) Retaining Ring

(2) Spring Seat

(3) Springs

(4) Piston Assembly

(5) Third Clutch Drum

Disassemble

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.

DRemove the tool.

DRemove retaining ring (1).

248RS007

2.Release the spring seat (2).

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

DRemove 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.

Reassembly

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

the transmission. Lubricate the seal lip with

transmission fluid.

DInstall piston assembly (4) into the third clutch drum

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

protect the outer seal during installation.

DRemove the seal installer.

248RS008

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

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

DCompress 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.

DInstall spring seat retaining ring (1).

DRemove the piston spring compressor and adapter.

Sprag Unit

Disassembled View

248RS009

Legend

(1) Retaining Ring

(2) Sprag Outer Race

(3) Ring

(4) Sprag Assembly

(5) Ring

(6) Third Clutch Hub and Sun Gear Assembly

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.Install sprag outer race and retaining ring assembly

over the sprag cage assembly.

DPlace third clutch hub and sun gear assembly on a

flat surface, sun gear facing up. Place sprag outer

race and sprag assembly over 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

Second Clutch

Disassembled View

247RW001

Legend

(1) Retaining Ring

(2) Ring Gear

(3) Retaining Ring

(4) Spacer

(5) Clutch Plates

(6) Waved W asher

(7) Retaining Ring

(8) Spring Seat

(9) Springs

(10) Piston Assembly

(11) Second Clutch Drum

Disassembly

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

(11).

2.Remove ring gear (2), retaining ring (3), and spacer

(4).

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

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

to compress the spring seat (8).

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).

DLubricate 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.

DRemove the installer.

247RS007

2.Install twenty-two piston springs (9) and spring seat

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

ring (7) onto spring seat.

DUse the J–23327 compressor to compress the

piston springs.

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

DRemove the compressor.

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

a steel plate and alternate with lined plates.

DAlign 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

Legend

(1) Snap Ring

(2) Cover

(3) Spring

(4) Piston Assembly

Disassembly

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

case.

DCompress piston cover then remove snap ring.

242RS007

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

adapter to center hole of cover.

DUse 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.

Reassembly

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

push the piston into position, using suitable diameter

tube.

DRemove the piston fitter.

244RS006

2.Install spring and cover.

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

tool.

DInstall snap ring in groove.

DRemove the compressor tool.

242RS007

Reverse Clutch Piston and Center Support

Disassembled View

242RS006

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

Disassembly

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

then compress the spring seat.

DRemove retaining ring (1).

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

will cause damage to the spring seat.

DRemove 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.Install overrun lock out valve (13) and spring (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.Install gasket transfer plate/adapter case (8), center

support transfer plate (7), and gasket transfer

plate/center support (6).

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

Torque : 25 N•m (18 lb ft)

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

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

retaining ring (1).

DInstall the J–23327 compressor and compress

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

(1) in groove.

DRemove the tool.

Overrun Clutch and Turbine Shaft

Disassembled View

252RW005

Legend

(1) Snap Ring

(2) Overdrive Carrier Assembly

(3) Sun Gear

(4) Turbine Shaft

(5) Snap Ring

(6) Backing Plate

(7) Clutch Plates

(8) Snap Ring

(9) Overrun Roller Clutch Cam

(10) Roller Clutch Assembly

(11) Overrun 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.

DRemove 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

DCheck 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.Install the J–38555 inner installer on the drum (14).

DPre-install piston assembly into J–38555 outer

installer.

DInstall overrun clutch piston assembly (13). Use the

outer installer while pushing piston into drum (14).

DRemove the installer.

252RS012

252RS013

3.Install diaphragm spring (12).

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

faces upwards), overrun roller clutch assembly (10)

and cam (9).

5.Place snap ring loosely on spring retainer.

DHold the J–23327–91 compressor in a vise and

compress piston return spring with compressor.

DSet snap ring (8) in ring groove.

DRemove 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

Shift control Hydraulic

Control systems

Shift pattern Electronic

Control

systems

Shift quality Electronic

Lockup clutch Electronic

1st 2.856

2nd 1.618

Gear ratio 3rd 1.000

4th (O/D) 0.723

Reverse 2.000

Gear set Noiseless, high torque capability

Oil used

Name ATF DEXRON–III

Oil

used

Q’ty liter (qt) 8.6 (9.1)

Torque converter 2,200 ± 150 Stall speed (rpm)

Reverse clutch RC 4

Second clutch C2 6

Number of discs

Third clutch C3 6

Number

discs

Brake band Double wrap

Fourth clutch C4 2

Number of discs

Overrun clutch OC 1

Number

discs

Overdrive roller clutch OFW 10 Number of rollers

Principle sprag assembly PFW 26 Number of sprags

Input sun gear 30

Ravigneaux ty

Pinion gear 19

Ravigneaux

ty e

gear train Long pinion 23

(planetary gear

set)

Ring gear 90

set)

Long pinion 19 Number of teeth

Output sun gear 46

Overdrive carrier Sun gear 31

Overdrive

carrier

(planetary gear

Pinion gear 24

Ring gear 81

Torque Specifications

E07RY00019

E07RX008

E07RW003

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 clutch spring

compressor adapter

(Use with J–23075)

J–23084

Third clutch piston

installer

J–23327

Third clutch spring

compressor

J–23080–A

Second clutch piston

installer

ILLUSTRATION TOOL NO.

TOOL NAME

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 case

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 (Inside)

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

4L30–E Parts List

Case and Associated Parts

241RY00022

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) W ear 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) Plate, Transfer Adapter/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

(36) Case, Main

(37) Breather, Pipe

(38) Seal, O-ring

(39) Reservoir

(42) Gasket, Extension Case

(43) Extension Assembly

(44) Seal, O-ring/Speed Sensor

(45) Sensor Assembly, Speed

(46) Screw, Speed Sensor

(50) Seal, Extension Assembly

(51) Bearing, Needle/Extension

(52) Screw, Extension/Main 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, Valve Body

(71) Valve Body Assembly, Adapter Case

(72) Gasket, Adapter Valve Body

(73) Plate, Adapter Valve Body/T ransfer

(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) Filter Oil

(80) Harness Assembly, Main Case

(82) Roller and Spring Assembly, Manual Detent

(84) Valve Body Assembly, Main Case

(85) Ball, Check

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

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

(88) Gasket, Transfer/Main Case

(89) Screw, Transfer 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 Piston

(103) Spring, Return/Servo Piston

(104) Gasket, Adapter Case/Transfer Plate

(105) Powertrain Control Module

(106) Servo Piston Assembly

Pump Assembly

241RS019

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 Body Assemblies

244RS009

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) Spring, Valve Low Pressure Control

(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) Solenoid Assembly, Band Control PWM

(324) Screen Assembly, PWM Solenoid

(325) Plug, Screen

(326) Valve, Manual

243RW003

Legend

(401) Body, Valve/Adapter Case

(402) Screw, Solenoid Force Motor

(403) Retainer, Force Motor

(404) Solenoid, Force Motor

(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, Force Motor

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

(417) Plug Retainer

Overdrive Internal Components

252RW003

Legend

(501) Retainer, 4th Clutch

(502) Plate, 4th Clutch (Steel)

(503) Plate Assembly, 4th Clutch (Lined)

(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) Ring, 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 Components

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, Spring/2nd Clutch

(625) Plate, 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 Clutch (Lined)

(644) Washer, Thrust/Input Sun

(645) Bearing, Input Shaft/Gear Assembly

(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, Parking Lock

(672) Wheel, Speed

(673) Ring, Retaining

(675) Bearing, Thrust Assembly

Center Support Assembly

241RS010

Legend

(701) Center Support

(702) Retainer Plate

(703) Plug, Lockout

(704) Spring, Overrun Lockout

(705) Valve, Overrun Lockout