Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–1

Page 7D4–1

Section 7D4

Automatic Transmission – 4L65E –

On-vehicle Servicing

ATTENTION

Before performing any service operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................4

1.1 General Service Information................................................................................................................................. 4

Description............................................................................................................................................................. 4

Service Information ............................................................................................................................................... 4

2 Maintenance Operations........................................................................................................................5

2.1 Transmission Fluid................................................................................................................................................5

Transmission Fluid Level......................................................................................................................................5

Transmission Fluid Colour....................................................................................................................................6

2.2 Reverse Flush and Flo w Rate Test....................................................................................................................... 7

Reverse Flush ........................................................................................................................................................ 7

Flow Rate Test........................................................................................................................................................ 8

3 Service Operations.................................................................................................................................9

3.1 Fluid Change and Filter Replacement.................................................................................................................. 9

Remove................................................................................................................................................................... 9

Reinstall................................................................................................................................................................ 11

3.2 Selector Linkage and Rod, Except AWD............................................................................................................ 12

Remove................................................................................................................................................................. 12

Inspect .................................................................................................................................................................. 12

Reinstall................................................................................................................................................................ 12

3.3 Selector Cable Assembly, AWD.......................................................................................................................... 13

Remove................................................................................................................................................................. 13

Reinstall................................................................................................................................................................ 14

3.4 Shift Selector Assembly, Except Coupe and AWD........................................................................................... 16

Remove................................................................................................................................................................. 16

Disassemble......................................................................................................................................................... 17

Lower Housing Assembly................................................................................................................................. 17

Patch Harness and Switch............................................................................................................................... 20

Upper Cover, Boot and Selector Knob............................................................................................................. 22

Selector Lever Assembly.................................................................................................................................. 24

Reinstall................................................................................................................................................................ 26

3.5 Shift Selector Assembly, Coupe......................................................................................................................... 27

Remove................................................................................................................................................................. 27

Disassemble......................................................................................................................................................... 28

Lower Housing Assembly................................................................................................................................. 28

Patch Harness and Switch............................................................................................................................... 31

Upper Cover, Boot and Selector Knob............................................................................................................. 33

Selector Lever Assembly.................................................................................................................................. 35

Reinstall................................................................................................................................................................ 37

Techline

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–2

Page 7D4–2

3.6 Shift Selector Assembly, AWD ........................................................................................................................... 38

Remove................................................................................................................................................................. 38

Disassemble......................................................................................................................................................... 39

Lower Housing Assembly................................................................................................................................. 39

Patch Harness and Switch............................................................................................................................... 42

Upper Cover, Boot and Selector Knob............................................................................................................. 42

Reinstall................................................................................................................................................................ 42

3.7 Neutral Start and Back-up Lamp Switch, Except AWD ..................................................................................... 43

Remove................................................................................................................................................................. 43

Reinstall................................................................................................................................................................ 43

Adjust.................................................................................................................................................................... 44

3.8 Neutral Start and Back-up Lamp Switch, AWD ................................................................................................. 45

Remove................................................................................................................................................................. 45

Reinstall................................................................................................................................................................ 46

Adjust.................................................................................................................................................................... 46

3.9 Vehicle Speed Sensor, Except AWD.................................................................................................................. 47

Remove................................................................................................................................................................. 47

Reinstall................................................................................................................................................................ 47

3.10 Vehicle Speed Sensor, AWD............................................................................................................................... 48

Remove................................................................................................................................................................. 48

Reinstall................................................................................................................................................................ 48

3.11 Manual Shaft Oil Seal .......................................................................................................................................... 49

Replace................................................................................................................................................................. 49

3.12 Transmission Support and Mount, Except Coupe and AWD........................................................................... 51

Remove................................................................................................................................................................. 51

Reinstall................................................................................................................................................................ 51

3.13 Transmission Support and Mount, Coupe ......................................................................................................... 53

Remove................................................................................................................................................................. 53

Reinstall................................................................................................................................................................ 53

3.14 Extension Housing and Rear Bush, Except AWD............................................................................................. 55

Remove................................................................................................................................................................. 55

Reinstall................................................................................................................................................................ 56

3.15 Extension Housing Oil Seal, Except AWD......................................................................................................... 57

Replace................................................................................................................................................................. 57

3.16 Transmission Support and Adaptor Housing, AWD......................................................................................... 58

Remove and Reinstall.......................................................................................................................................... 58

3.17 Shift Solenoid Locations..................................................................................................................................... 59

Location and Identification ................................................................................................................................. 59

3.18 1 – 2 Accumulator Assembly.............................................................................................................................. 60

Remove................................................................................................................................................................. 60

Clean and Inspect................................................................................................................................................ 60

Reinstall................................................................................................................................................................ 60

3.19 Control Valve Body Harness............................................................................................................................... 61

Remove................................................................................................................................................................. 61

Reinstall................................................................................................................................................................ 63

3.20 Control Valve Body.............................................................................................................................................. 65

Remove................................................................................................................................................................. 65

Disassemble, Clean, Inspect and Reassemble.................................................................................................. 66

Reinstall................................................................................................................................................................ 66

3.21 Spacer Plate, Check Balls, Filter Screens and 3 – 4 Accumulator .................................................................. 70

Remove................................................................................................................................................................. 70

Clean and Inspect................................................................................................................................................ 71

Reinstall................................................................................................................................................................ 72

3.22 Filler Tube and Breather Hose............................................................................................................................ 75

Remove................................................................................................................................................................. 75

Reinstall................................................................................................................................................................ 76

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–3

Page 7D4–3

3.23 Transmission Cooler Lines and Hoses.............................................................................................................. 77

Arrangement......................................................................................................................................................... 77

Radiator............................................................................................................................................................ 77

Fluid Cooler Lines ............................................................................................................................................ 78

Radiator Cooler Hoses / Lines............................................................................................................................ 78

Remove............................................................................................................................................................ 78

Reinstall ........................................................................................................................................................... 80

Transmission Fluid Lines.................................................................................................................................... 81

Remove............................................................................................................................................................ 81

Reinstall ........................................................................................................................................................... 82

3.24 Transmission Assembly – Except AWD ............................................................................................................ 83

Remove................................................................................................................................................................. 83

Reinstall................................................................................................................................................................ 86

3.25 Transmission Assembly – AWD......................................................................................................................... 88

Remove................................................................................................................................................................. 88

Reinstall................................................................................................................................................................ 91

4 Specifications.......................................................................................................................................93

5 Torque Wrench Specifications............................................................................................................94

6 Special Tools ........................................................................................................................................95

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–4

Page 7D4–4

1 General Information

This Section describes the removal and rei nstallation procedures of the four speed 4L65E h ydra-matic automatic

transmission as well as the service operatio ns which can be performed with the transmission still fitted to the vehicle.

1.1 General Service Information

Description

For rear wheel drive (RWD) vehicles the shift selector mechanism is linked to the transmission manual shaft with a

selector rod. An extension housing is fitted to the rear of the transmission case with the transmission mount and support.

For all wheel drive (AWD) vehicles the shift selector mechanism is linked to the transmission manual shaft with a selector

cable. An adaptor housing a nd transfer case are fitted to the rear of the transmission case with the support mount

attached to the rear mounting bracket, for description and service o peration refer to

Section 7F Transfer Case and Adaptor Ho using.

The four speed 4L65E hydra- matic automatic transmission is fitted with a filler tube, a breather hose and a vent pipe for

hot fluid overflow.

The transmission fluid is driven through a cooler within the radiator via the fluid lines and cooler hoses / lines to maintain

normal operating temperature.

Service Information

Throughout the service operations within this

Section, when handling retaining clips, using

compressed air o r cleaning flu ids, w ear safety

equipment to avoid personal injury.

Refer to Section 7D1 Automatic transmission – 4L65E – General Information for the following:

• information relating to mechanical and electrical operations,

• abbreviations, transmission specificati ons, special tools and torque wrench specifications,

• servicing, cleaning and inspe c tion procedure recommendations.

It is essential to read and understand the General Information, Warnings, Cautions and Service Notes contained in that

same Section, before any service operation is performed on the four speed 4L65E hydra-matic automatic transmission or

any associated components.

Failure to comply with the procedur es and service notes can affect the reliable and efficient operation of this automatic

transmission.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–5

Page 7D4–5

2 Maintenance Operations

2.1 Transmission Fluid

When adding or changing the transmission fluid, use only the recommended automatic transmission fluid , refer to

Section 0B Lubrication and Se rvice .

For the automatic transmission fluid diagnos is, refer to

Section 7D3 Automatic Transmission – 4L65E – Hydraulic and Mechanical Diagnosis.

Transmission Fluid Level

NOTE

Carry out this operation with the transmission at

normal operating temperature (82 – 94°C), a s the

temperature greatly affects the fluid level.

1 Drive the vehicle for a distance of at least 25 km to bring the transmissi on up to normal operating temperature.

If the transmission is not at normal operating

temperature and the correct procedure is not

followed, the result could b e a false reading of

the fluid level on the transmission fluid

indicator.

2 If the vehicle has been operated un der any of the following conditions, switch the engine off and allow the

transmission to cool for approximatel y thirty minutes:

• in high ambient temperatures abov e 32° C,

• at sustained high speeds,

• in heavy stop / start city traffic during hot weather, or

• towing.

3 Park the vehicle on level ground.

4 Move the gear selector to the Park position and apply the park brake.

5 Allow the engine to idle for 3 minutes with the accessories turned off.

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Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–6

Page 7D4–6

6 Lift the locking lever (1) on the transmission fluid

indicator, then remove the indicator from the filler

tube (2) and check the fluid colour, con ditio n and level.

Do not overfill the transmission. Overfilling

can cause aeration resulting in fluid loss,

shift complaints and possible damage to the

transmission.

7 If the transmission fluid level is low, add only enough

of the recommended fluid until its level shows onto the

crosshatch hot area (3) of the fluid indicator.

Figure 7D4 – 1

Transmission Fluid Colour

New transmission fluid is red in colour due to a dye that is added to the fluid so it can be distinguished from other oils and

lubricants. The red dye is not perma nent and as such, is not an indicator of the quality of the fluid.

As the vehicle is driven the transmission fluid will quickly look darker in colour and appear to be a light brown. A dark

brown colour with a distinctively burnt odour may indicate fluid deterioration and th e need for fluid replacement.

NOTE

A dark brown fluid colour observed, coupled with

a reported delayed shift patter n may only indicate

that fluid replacement is required. This is not a

definite indication of a potential transmission

failure.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–7

Page 7D4–7

2.2 Reverse Flush and Flow Rate Test

It is essential to perform a reverse flush and oil cooler flow rate test after any of the following:

• the transmission is repaired or replaced,

• fluid contamination is suspected, or

• whenever the oil pump and/or torque converter is replaced.

NOTE

The reverse flush must be completed prior to

conducting a flow rate test.

Reverse Flush

1 Disconnect both fluid lines at the transmission and cooler hoses / lines at the radiator cooler, refer to

3.23 Transmission Cooler Lines and Hoses.

2 Check the cooler hoses / lines to radiator cooler fittings sealing washers for damag e, replace as required.

To avoid personal injury, wear safety glasses

when using compressed air.

3 Carefully check the radiator cooler lower fitting to see if any foreign material is evident at this point. If foreign

material is found, remove it with a suitable tool and/or compressed air at a reduc ed pressure of approximately

345 kPa blown in the reverse direction through the cooler.

4 Using compressed air at a reduce pressure of approximately 345 kPa blown in a revers e direction, clean the fluid

lines, cooler hoses / lines and if required any external cooler (where fitted).

5 Reconnect the fluid outlet line to the transmission and both cooler hoses / lines to the radiator cooler fittings,

refer to 3.23 Transmission Cooler Lin es an d Hoses .

NOTE

Do not reconnect the fluid inlet line at the

transmission end. This line needs to be left

disconnected to perform the flo w rate test.

6 Perform the flow rate test, refer to Flow Rate Test in this Section.

NOTE

This will also flush the fluid lines, cooler hoses /

lines and cooler with transmission fluid.

7 If the flow rate is satisfactory, reconnect the fluid inlet line to the transmission,

refer to 3.23 Transmission Cooler Lin es an d Hoses .

8 Lower the vehicle, check and top up the transmission fluid to the correct level as required,

refer to 2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–8

Page 7D4–8

Flow Rate Test

Do not run the engine any longer than

absolutely necessary, as a fluid level too low

can cause aeration an d foaming.

1 Ensure the transmission fluid is at the recommended level or slightl y abo v e, refer to 2.1 Tr ansmission Fluid.

2 Disconnect the fluid inlet line at the transmis sion quick-connect fitting,

refer to 3.23 Transmission Cooler Lin es an d Hoses .

3 Place a suitable size containe r underneath the disconnected fluid inlet line.

4 With the selector lever in the P position, start the engine and observe the fluid flow into the container after all the air

bubbles have ceased and a steady flow is evident. Measure the flow rate over 20 seconds and ensure it is within

the specification.

Transmission fluid flow rate specificati on per 20 Seconds:

Temperature:

Ambient............................................................ 0.7 Litres

86° – 93° C ...................................................... 1.2 Litres

5 If the flow rate is less than the specification, the cause of the low flow rate must be located and rectified.

Possible cause could include:

• restricted cooler within the radiator tank,

• damaged or restricted external cooler, where fitted,

• kinked or damaged transmission flu id lines and/or cooler hoses / lines, or

• internal transmission fault such as a faulty pump.

6 Reinstall the fluid inlet line to the transmission quick-connect fitting,

refer to 3.23 Transmission Cooler Lin es an d Hoses .

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–9

Page 7D4–9

3 Service Operations

3.1 Fluid Change and Filter Replacement

LT Section No. — 04–220

To avoid personal injury take note of the

following:

• Avoid accidental hot oil spillage by

performing fluid change only when the

transmission fluid is cold.

• Wear safety glasses and gloves when

using compressed air and cleaning fluids.

Remove

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information.

2 Clean all dirt from around the oil pan and the transmission case.

3 Place a suitable sized drain tray under the

transmission.

4 Hold the oil pan (1) in place a nd remove the oil pan

bolts (2) from the front and both sides.

NOTE

Leave the three rear oil pan b olts in place.

5 Loosen the three rear oil pan bolts by about 4 turns

each. While still supporting the oil pan, lightly tap the

sides with a rubber hammer to break the gasket (3)

seal.

6 Lower the front of the oil pan and drain the fluid into a

suitable container.

7 Remove the three remaining r ear bolts and the oil pan

from the transmission.

8 Remove the oil pan gasket and discard. Figure 7D4 – 2

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Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–10

Page 7D4–10

9 Remove the oil filter (1) by pulling down while twisting

the filter and remove it from the transmission.

10 Open the filter by prising the metal crimping a way from

the top of the filter and pull it apart.

11 Inspect the filter material for particles that may indicate

evidence of a potential transmission problem.

Examples of the type of material are:

• clutch friction material,

• bronze slivers, indicating bush wear and

• steel particles.

Figure 7D4 – 3

Take care not to scratch the oil pump bore,

as fluid leakage could occur from this point

or the pump may suck in air, causing the

fluid to aerate.

12 Using suitable circlip pliers (1) or a two legged puller

and slide hammer, remove the oil filter seal (2) taking

care not to scratch the oil pump bore (3) during the

process. Discard the seal.

Figure 7D4 – 4

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–11

Page 7D4–11

Reinstall

1 Clean the oil pan in a commercially available cleaning fl uid and blow dry using compressed air.

NOTE

Ensure all traces of the old gasket are removed

from the transmission and oil pan.

2 Wipe the transmission case gasket mating s urface with a clean lint free cloth.

3 Lubricate a new oil filter seal (1) with clean

transmission fluid and install into the oil pump bore (2)

using a suitable sized socket or piec e of tubing.

4 Install a new filter into the transmission case.

5 Check if the magnet is functional and l ocated in the

designated position in the oil pan. Install a new gasket

and reinstall the oil pan.

6 Tighten the bolts attaching the oil pan to the correct

torque specification.

Oil pan attaching bolt

torque specification............................................12.0 Nm

Figure 7D4 – 5

7 Lower vehicle and add the recommended automatic transmission fluid, approx imately 5.0 litres for the GEN III V8

engine.

8 Operate the vehicle for about 24 km or until normal transmission operating temperature is reached,

refer to 2.1 Transmission Fluid.

9 Ensure there are no fluid leaks from the oil pan area, rectify as required.

10 Check and top up the transmission fluid to the correct level as required, refer 2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–12

Page 7D4–12

3.2 Selector Linkage and Rod, Except AWD

LT Section No. — 04–170

Remove

1 Position the transmission selector lever to the Park position.

2 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information.

3 Remove the following parts from the lower end of the

selector linkage (1):

a locking bolt (2),

b dished washer (3),

c flat washer (4),

d insulator (5) and

e sleeve (6).

4 Slide the trunnion (7) out of the selector rod (8).

5 Hold the transmission manua l shaft linka ge (9) with an

adjustable wrench and remov e the attachi ng nut (10).

6 Remove the linkage and selector rod assembly from

the transmission manual shaft (11).

Figure 7D4 – 6

Inspect

Inspect all components for wear and/or damage, repl ace as required.

Reinstall

Reinstallation of the selector linkage and rod is the reverse of the removal procedure, noting the following:

1 Tighten the manual shaft linkage (9) attaching nut (10) to the correct torque specification, refer to Figure 7D4 – 6.

Manual shaft linkage attaching nut

torque specification.................................15.0 – 35.0 Nm

2 Ensure the transmission selector lever is in the Park position.

3 Position the manual shaft linkage in the Park position and then tighten the selector rod locking bolt (2) to the correct

torque specification.

Selector rod locking bolt

torque specification.................................15.0 – 35.0 Nm

4 Ensure the engine can onl y be started with the transmission selector lever in Park or Neutral position and the back-

up lamps work correctly. If required, adjust the neutral start and back-up lamp switch, refer to

3.7 Neutral Start and Back-up Lamp Switch, Except AW D.

5 Lower the vehicle and check if t he gear selection operates correctly.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–13

Page 7D4–13

3.3 Selector Cable Assembly, AWD

LT Section No. — 04–170

Remove

1 Remove the following components, refer to Section 1A3 Instrument Panel and Console:

a floor console cover,

b lower extension side trim panels and

c floor console assembly.

2 Position the transmission selector lever to the Park

position.

3 Using a small flat blade scre wdriver (1), gentl y prise

the upper end of the selector cable (2) from the pin on

the shift selector lever linkage.

NOTE

To gain clear access to the cable end, release

the two rear selector housing pegs (3) from the

base and lift up.

Figure 7D4 – 7

To prevent personal injury, wear safety

glasses when removing spring loaded

retainers.

4 From inside the vehicle, use a flat blade screwdriver to

remove the outer cable retainer (1) from the front of

the shift selector base (2).

Figure 7D4 – 8

5 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

6 Lower the rear of the transfer case to gain access to the selector cable upper bracket to floor pan attaching nuts,

refer to Section 7F Transfer Case and Adapter Housing.

7 From under the vehicle, remove the two nuts attaching the selector cable upper bracket and seal to the floor pan.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–14

Page 7D4–14

To prevent personal injury, wear safety

glasses when removing spring loaded

retainers.

8 From under the vehicle, use a flat blade

screwdriver (1) to release the retainer (2) securing the

outer cable to the transmission bracket (3).

Figure 7D4 – 9

9 Using a small flat blade screwdriver (1) prise the

selector cable end (2) from the transmission external

manual shaft linkage (3).

Figure 7D4 – 10

NOTE

Do not to lose the inner lock during the following

operation.

10 With your fingers slide back the adjustment lock (1)

and then using a small screwdriver, push ou t the white

square inner lock (2).

11 Dislodge the selector cable upper bracket and seal

from the floor pan and remove the selector ca ble

assembly from inside the vehicle.

Figure 7D4 – 11

Reinstall

1 Thread the selector cable ass embly through the aperture in the floor pan until the cable upper bracket studs can be

inserted through the floor pan hol es.

2 Install the selector cable upper end fitting (2 ) to the shift selector linkage pin by pushing it inwards until the fitting is

installed past the pin flange, refer to Figure 7 D4 – 7.

3 Engage the groove in the outer cable upper end with the slot in the shift selector base, then install a new

retainer (1) to secure, refer to Figure 7D4 – 8.

4 Check if the rubber grommet is correctly fitted at the outer cable upper end.

5 From under the vehicle, reinst all the two nuts attaching the selector cable upper bracket and tighten to the correct

torque specification.

Selector cable upper bracket

to floor pan attaching nut

torque specification.................................12.0 – 18.0 Nm

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–15

Page 7D4–15

6 After checking if the selector cable assembly is routed correctly, raise the rear of the transfer case and reinstall to

the vehicle underbody, refer to Section 7F Transfer Case an d Adapter Housing.

7 Reinstall the selector cable lower end (2) to the transmission external manual shaft linkage pin, ensure it is fully

installed to the pin, refer to Figure 7D4 – 10. Leave the cable adjustment lock and the whit e square inner lock in the

released position as the cable must be adjusted after installation.

To prevent personal injury, wear safety

glasses when installing spring loaded

retainers.

8 From under the vehicle, reinst all the outer cable retainer (2). Ensure it is fully engaged and in the correct position,

which is forward of the bracket (3) that is bolted to the transmission case, refer to Figure 7D4 – 9.

9 Check if the rubber grommet is correctly fitted at the cable lower end.

10 Ensure the transmission external manual shaft linkage and the shift selector lever are in the P position.

11 Push the white square inner lock (1) in ward to enga ge

it with the serrated cable end.

Figure 7D4 – 12

12 Secure the adjuster by sliding the adjustme nt lock (1)

forward.

Figure 7D4 – 13

13 Ensure the engine can onl y be started with the transmission selector lever in Park or Neutral position and the

back-up lamps work correctly. If required, adjust the neutral start and back-up lamp switch, refer to

3.8 Neutral Start and Back-up Lamp Switch, AW D.

14 Lower the vehicle and check if t he gear selection operates correctly.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–16

Page 7D4–16

3.4 Shift Selector Assembly, Except Coupe

and AWD

LT Section No. — 04–190

Remove

1 Remove the following components, refer to Section 1A3 Instrument Panel and Console:

a floor console cover,

b lower extension side trim panels and

c floor console assembly.

2 At the rear of the shift selector assembly, disconn ect

the harness connector (1) from the selector patch

harness (2).

NOTE

The shift selector assembly needs to be

disconnected and detached from the floor pan

only to service the base and selector lever. The

lower housing and associated components can

be separated from the base for servicing.

3 Raise the vehicle and suppor t in a safe manner,

refer to Section 0A General Information for the location

of support points.

4 From underneath the vehicle, remove the locking bolt

and disconnect the selector rod and trun nion from the

selector linkage, refer to 3.2 Selector Linkage and

Rod, Except AWD.

Figure 7D4 – 14

5 From underneath the vehicle, remove the four nuts (1)

attaching the shift selector lever assembly to the floor

pan.

6 From inside the vehicle, lift the shift selector lever

assembly from the floor pan.

Figure 7D4 – 15

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–17

Page 7D4–17

Disassemble

Lower Housing Assembly

Remove

NOTE

The lower housing assembly can be

disassembled without the base being detached

from the floor pan.

1 With the selector lever in the D position, use a suitable

size Torx bit and remove the screw (1) on the forward

side of the lever (2).

NOTE

This is also the recommended reassembly

position.

Figure 7D4 – 16

2 From the rear of the selector base, use a small flat

blade screwdriver (1) to gently prise the locking tab on

the patch harness connector (2) and push the

connector away from its support on the shift selector

base (3).

Figure 7D4 – 17

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–18

Page 7D4–18

3 Disconnect the lower housing (1) from the base (2) by

pressing the tang (3) on each of the retaining legs.

NOTE

There are two tangs at the front and one at the

rear of the lower housing.

4 Lift the lower housing from the base together with the

switch(s), patch wiring harness, upper cover, boot and

selector knob.

5 As required, lift the insulator (4) from the base.

Figure 7D4 – 18

Reinstall

1 Ensure the PRNDL indicator slide, in the lower

housing (1), is at the D position with the red colour

showing opposite the D in the PRNDL lens (2).

2 Ensure the insulator (3) is undamaged and reinstall it

to the base (4).

3 Ensure the selector lever is in the D position and

reinstall the lower housing assembly over the selector

lever, engage each of the three retaining legs with the

base.

NOTE

Check if the PRNDL indicator slide pin is

engaged with the slot in the selector lever.

Figure 7D4 – 19

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–19

Page 7D4–19

NOTE

If the knob button (4) and spring have not been

removed, some manoeuvring may be necessary

to re-engage the selector lever.

4 Re-engage the selector lever knob (1) with the

selector lever, aligning the control rod with the hole in

the selector knob.

5 Check the correct engagement of the PRNDL indicator

by moving the selector lever. If the coloured portion (2)

does not move with the lever, engagement is incorrect.

To rectify, separate the lower housing from the base

and repeat procedure steps 3 to 5.

6 Reinstall the selector knob attaching Torx screw (3)

and tighten to the recommended torque spec ification.

Selector knob attaching Torx screw

torque specification.....................................1.0 – 3.0 Nm

7 If required, reinstall the knob button (4) and spring,

push the button down until the two locking tangs are

engaged.

Figure 7D4 – 20

8 Secure the patch harness connector (1) to its support

on the rear of the selector base (2).

Figure 7D4 – 21

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–20

Page 7D4–20

Patch Harness and Switch

Remove

1 As required, separate the lower housing from

the base as described in this Section, refer to

Lower Housing Assembly.

2 Remove the selector indicator lamp a nd holder (1)

from the lower housing by turning the lamp holder 90°

counter-clockwise and pull it o utward.

Figure 7D4 – 22

3 Disengage the retaining l ugs and remove the patch

harness connector (1) from the transmission power

control switch (2) and where fitted, the connector (3)

from the traction control switch (4).

NOTE

The wiring for the traction control switch

connector (where fitted), is taped to the PRNDL

indicator lamp wiring (5).

4 Remove the patch harness from the lo wer housing.

Figure 7D4 – 23

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–21

Page 7D4–21

Take note of the locating lug on the switch

body to ensure the switch is in the correct

orientation of when reinstalled.

5 Remove the power control switch (PWR) (1) as

follows:

a Using a small flat blade screwdriver (2) lever one

of the switch retaining tangs from under the

lower housing to free the switch.

b Cock the switch to one side to release the

second tang and remove the switch from the

lower housing.

6 Repeat the procedure to remove the traction control

switch (T/C) where fitted. Figure 7D4 – 24

Reinstall

1 Reinstall the switch(s) to the lower housing ensuring the locating lug on the s witch bod y engages with the slot in

the lower housing, secure the switch with the retaining tangs.

NOTE

If the vehicle is equipped with traction control, the

correct location for the corresponding switch is

behind the PRNDL indic ator lens.

2 Reinstall the patch harness connector(s) (1) to the

PWR switch (2) and where fitted to the T/C switch (3).

NOTE

Both connectors are the same colour (white).

The wiring for the traction control switch

connector (where fitted), is taped to the PRNDL

indicator lamp wiring as this switch is always on

the same side as the lamp (4).

3 Insert the selector indicator lamp and holder (4) in the

lower housing and turn it clockwise to secure.

4 As required, reinstall the lower housing to the

base as described in this Section, refer to

Lower Housing Assembly.

Figure 7D4 – 25

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–22

Page 7D4–22

Upper Cover, Boot and Selector Knob

Remove

1 As required, separate the lower housing from

the base as described in this Section, refer to

Lower Housing Assembly.

2 While holding the lower housing (1) in an inverted

position, gently prise the lug (2), four places and free

the upper cover (3) from the lower housing.

3 Lift the lower housing and separate from the shift

selector knob, boot and upper cover assemb ly.

NOTE

If the lower housing assembly is not inverted

before separation, the bo ot will probably become

dislodged from the locating tangs in the upper

cover.

Figure 7D4 – 26

4 If required, remove the boot from the upper cover

locating tangs being careful not to dislodge or damage

the PRNDL indicator lens in the process.

5 Turn the boot (1) inside out over the selector knob, cut

the plastic tie (2) attaching the boot and rem ove the

boot from the selector knob.

NOTE

The plastic tie is a unique design and is

markedly different from the usual cable tie.

Figure 7D4 – 27

The control rod button is spring loaded and

may fly free once dislodged.

6 If required, dismantle the selector knob (1) as follows:

a Using a small knife (2) or similar, free the lugs

securing the control rod button (3) to the knob,

remove the button and spring (4).

b Remove the two screws (5) attaching the

bezel (6) and separate the knob components.

Figure 7D4 – 28

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–23

Page 7D4–23

Reinstall

1 If installing a new boot, turn it inside out over the shift selector and firmly secure it with the plastic tie included with

the new boot, trim any excess length and disc ard.

NOTE

The plastic tie is a uniqu e design and is mark edly

different from the usual cable tie.

2 With the upper cover (1) inverted, locate the boot (2)

over each of the upper cover locating tangs (3),

working gradually around until every tang is covered.

NOTE

The weight of the selector knob is sufficient to

keep the boot engaged with the tangs.

Figure 7D4 – 29

NOTE

Before reassembling the upper cover to the

lower housing note the following:

• Proceed with the parts in an inverted position

to reduce the possibility of the boot

dislodging from the retaining tangs.

• Ensure the colored indictor is in line with the

two PRNDL display lamp holes (1). This is

the approximate position for correct

reassembly.

3 Engage the tab (2), four places, on the upper cover (3)

with the retaining lugs on the lower housing (4).

NOTE

With the tabs engaged, the boot will be clamped

and can no longer become disengaged.

Figure 7D4 – 30

4 If required, attach the bezel (6) to the knob (1) with the two screws (5), tighten to the correct torque specification,

refer to Figure 7D4 – 28.

Selector knob bezel attaching screw

torque specification.....................................1.0 – 2.0 Nm

NOTE

Reinstall the spring (4) and control rod button (3)

to the knob after the lower housing has been

reinstalled to the base.

5 As required, reinstall the lower housing to the base as described in this Section, refer to Lower Housing Assembly.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–24

Page 7D4–24

Selector Lever Assembly

Remove

1 As required, remove the shift selector assembly as described in this Section, refer to Remove.

2 As required, separate the lower housing from the base as described in this Section,

refer to Lower Housing Assembly.

NOTE

Ensure the locking bolt, trunnion and associated

parts have previously been removed from the

lower end of the selector linkage, refer to

3.2 Selector Linkage and Rod, Except AWD.

This is necessary to provide clearance for the

removal of the selector lever from the base.

3 Remove the outer seal (1) from the selector lever.

Figure 7D4 – 31

4 Remove the selector lever lock ing piece (1) using a

small screwdriver (2) to lever the locking tang free

while pulling on the locking piece with long nosed

pliers (3).

Figure 7D4 – 32

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–25

Page 7D4–25

NOTE

When removing the selector lever assembly:

• While it will be necessary to manoeuvre the

selector lever somewhat, sufficient space is

provided to overcome any need to apply

force for the removal.

• The bush will probably remain in the base.

5 Push the selector lever assembly (1) inwards to

release the inner support pin (2) and bush (3) and then

lift the selector lever from the base (4) to remove it.

Further disassembly of the selector lever is

not recommended as there is a possibility

that, during reinstallation of the roll pin, the

selector lever will be cracked unless

sophisticated jigs are used. For this reason,

the shift lever is only serviced as an

assembly.

Figure 7D4 – 33

Reinstall

1 Inspect the selector lever inner bush (1) for damage,

replace as required. Lubricate the inner bush with a

multi-purpose chassis grease such as NLGI No. 1

Lithium grease or equivale nt.

2 Lubricate the split inner suppor t bush (2) with a multi-

purpose chassis grease such as NLGI No. 1 Lithium

grease or equivalent and re install the bush to the

selector lever pin aligning the split in the bush with the

key on the pin.

3 Align the inner support bush with the aperture in the

base and push it across to fully install the se lector

lever (3) in the base.

Figure 7D4 – 34

4 Using long nosed pliers, reinstall the selector lever

locking piece (1) into the base.

NOTE

An audible click will indicate if the tang on the

locking piece is correctly inserted in the base.

Figure 7D4 – 35

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–26

Page 7D4–26

5 Apply a smear of multi-purpose chassis grease such

as NLGI No. 1 Lithium grease or equivalent to the

outer seal (1) and install it over the selector lever.

6 Reinstall the lower housin g on the base as described

in this Section, refer to Lower Housing Assembly.

7 Reinstall the shift selector assembly as described in

this Section, refer to Reinstall.

Figure 7D4 – 36

Reinstall

1 Clean the mating surfaces of floor pan and inspect the

base seal for damage, replace as required.

2 From inside the vehicle, reinstall the shift selector

assembly (1) to the floor pan.

3 At the rear of the shift selector assembly, reconnect

the harness connector (2) to the selector patch

harness (3).

4 Raise the vehicle and suppor t in a safe manner,

refer to Section 0A General Information for the location

of support points.

5 From underneath the vehicle, install the four nuts (4)

attaching the shift selector assembly to the floor pan,

tighten to the correct torque specification.

Selector base attaching nut

torque specification.................................12.0 – 18.0 Nm

6 Reconnect the selector rod and trunni on to the

selector linkage, refer to 3.2 Selector Linkage and

Rod, Except AWD.

7 Reinstall the following components, refer to

Section 1A3 Instrument Panel and Co nsole:

a floor console assembly,

b lower extension side trim panels and

c floor console cover.

Figure 7D4 – 37

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–27

Page 7D4–27

3.5 Shift Selector Assembly, Coupe

LT Section No. — 04–190

Remove

1 Remove the following components, refer to Section 1A3 Instrument Panel and Console:

a floor console cover,

b lower extension side trim panels and

c floor console assembly.

2 At the rear of the shift selector assembly, disconn ect

the harness connector (1) from the selector patch

harness (2).

NOTE

The shift selector assembly needs to be

disconnected and detached from the floor pan

only to service the base and selector lever. The

lower housing and associated components can

be separated from the base for servicing.

3 Raise the vehicle and suppor t in a safe manner,

refer to Section 0A General Information for the location

of support points.

4 From underneath the vehicle, remove the locking bolt

and disconnect the selector rod and trun nion from the

selector linkage, refer to 3.2 Selector Linkage and

Rod, Except AWD.

Figure 7D4 – 38

5 From underneath the vehicle, remove the four nuts (1)

attaching the shift selector lever assembly to the floor

pan.

6 From inside the vehicle, lift the shift selector lever

assembly from the floor pan.

Figure 7D4 – 39

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–28

Page 7D4–28

Disassemble

Lower Housing Assembly

Remove

NOTE

The lower housing assembly can be

disassembled without the base being detached

from the floor pan.

1 With the selector lever in the D position, use a suitable

size Torx bit and remove the screw (1) on the forward

side of the lever (2).

NOTE

This is also the recommended reassembly

position.

Figure 7D4 – 40

2 From the rear of the selector base, use a small flat

blade screwdriver (1) to gently prise the locking tab on

the patch harness connector (2) and push the

connector away from its support on the shift selector

base (3).

Figure 7D4 – 41

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–29

Page 7D4–29

3 Disconnect the lower housing (1) from the base (2) by

pressing the tang (3) on each of the retaining legs.

NOTE

There are two tangs at the front and one at the

rear of the lower housing.

4 Lift the lower housing from the base together with the

traction control switch (T/C), patch harness, upper

cover, boot and selector knob.

5 As required, lift the insulator (4) from the base.

Figure 7D4 – 42

Reinstall

1 Ensure the PRNDL indicator slide, in the lower

housing (1), is at the D position with the red colour

showing opposite the D in the PRNDL lens (2).

2 Ensure the insulator (3) is undamaged and reinstall it

to the base (4).

3 Ensure the selector lever is in the D position and

reinstall the lower housing assembly over the selector

lever, engage each of the three retaining legs with the

base.

NOTE

Check if the PRNDL indicator slide pin is

engaged with the slot in the selector lever.

Figure 7D4 – 43

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–30

Page 7D4–30

NOTE

If the knob button (4) and spring have not been

removed, some manoeuvring may be necessary

to re-engage the selector lever.

4 Re-engage the selector lever knob (1) with the

selector lever, aligning the control rod with the hole in

the selector knob.

5 Check the correct engagement of the PRNDL indicator

by moving the selector lever. If the coloured portion (2)

does not move with the lever, engagement is incorrect.

To rectify, separate the lower housing from the base

and repeat procedure steps 3 to 5.

6 Reinstall the selector knob attaching Torx screw (3)

and tighten to the recommended torque spec ification.

Selector knob attaching Torx screw

torque specification.....................................1.0 – 3.0 Nm

7 If required, reinstall the knob button (4) and spring,

push the button down until the two locking tangs are

engaged.

Figure 7D4 – 44

8 Secure the patch harness connector (1) to its support

on the rear of the selector base (2).

Figure 7D4 – 45

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–31

Page 7D4–31

Patch Harness and Switch

Remove

1 As required, separate the lower housing from

the base as described in this Section, refer to

Lower Housing Assembly.

2 Remove the selector indicator lamp a nd holder (1)

from the lower housing by turning the lamp holder 90°

counter-clockwise and pull it o utward.

Figure 7D4 – 46

3 Disengage the retaining l ugs and remove the patch

harness connector (1) from the traction control

switch (2).

4 Remove the patch harness from the lo wer housing.

Figure 7D4 – 47

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–32

Page 7D4–32

Take note of the locating lug on the switch

body to ensure the switch is in the correct

orientation of when reinstalled.

5 Remove the traction control switch (T/C) (1) as

follows:

a Using a small flat blade screwdriver (2) lever one

of the switch retaining tangs from under the

lower housing to free the switch.

b Cock the switch to one side to release the

second tang and remove the switch from the

lower housing.

Figure 7D4 – 48

Reinstall

1 Reinstall the traction control switch (T/C) (1) to the

lower housing ensuring the locating lug on the switch

body engages with the slot in the lower housing,

secure the switch with the retaining tangs.

2 Reinstall the patch harness connector (2) to the T/ C

switch.

3 Insert the selector indicator lamp and holder (3) in the

lower housing and turn it clockwise to secure.

4 As required, reinstall the lower housing to the

base as described in this Section, refer to

Lower Housing Assembly.

Figure 7D4 – 49

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–33

Page 7D4–33

Upper Cover, Boot and Selector Knob

Remove

1 As required, separate the lower housing from

the base as described in this Section, refer to

Lower Housing Assembly.

2 While holding the lower housing (1) in an inverted

position, gently prise the lug (2), four places and free

the upper cover (3) from the lower housing.

3 Lift the lower housing and separate from the shift

selector knob, boot and upper cover assemb ly.

NOTE

If the lower housing assembly is not inverted

before separation, the bo ot will probably become

dislodged from the locating tangs in the upper

cover.

Figure 7D4 – 50

4 If required, remove the boot from the upper cover

locating tangs being careful not to dislodge or damage

the PRNDL indicator lens in the process.

5 Turn the boot (1) inside out over the selector knob, cut

the plastic tie (2) attaching the boot and rem ove the

boot from the selector knob.

NOTE

The plastic tie is a unique design and is

markedly different from the usual cable tie.

Figure 7D4 – 51

The control rod button is spring loaded and

may fly free once dislodged.

6 If required, dismantle the selector knob (1) as follows:

a Using a small knife (2) or similar, free the lugs

securing the control rod button (3) to the knob,

remove the button and spring (4).

b Remove the two screws (5) attaching the

bezel (6) and separate the knob components.

Figure 7D4 – 52

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–34

Page 7D4–34

Reinstall

1 If installing a new boot, turn it inside out over the shift selector and firmly secure it with the plastic tie included with

the new boot, trim any excess length and disc ard.

NOTE

The plastic tie is a uniqu e design and is mark edly

different from the usual cable tie.

2 With the upper cover (1) inverted, locate the boot (2)

over each of the upper cover locating tangs (3),

working gradually around until every tang is covered.

NOTE

The weight of the selector knob is sufficient to

keep the boot engaged with the tangs.

Figure 7D4 – 53

NOTE

Before reassembling the upper cover to the

lower housing note the following:

• Proceed with the parts in an inverted position

to reduce the possibility of the boot

dislodging from the retaining tangs.

• Ensure the colored indictor is in line with the

two PRNDL display lamp holes (1). This is

the approximate position for correct

reassembly.

3 Engage the tab (2), four places, on the upper cover (3)

with the retaining lugs on the lower housing (4).

NOTE

With the tabs engaged, the boot will be clamped

and can no longer become disengaged.

Figure 7D4 – 54

4 If required, attach the bezel (6) to the knob (1) with the two screws (5), tighten to the correct torque specification,

refer to Figure 7D4 – 52.

Selector knob bezel attaching screw

torque specification.....................................1.0 – 2.0 Nm

NOTE

Reinstall the spring (4) and control rod button (3)

to the knob after the lower housing has been

reinstalled to the base.

5 As required, reinstall the lower housing to the base as described in this Section, refer to Lower Housing Assembly.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–35

Page 7D4–35

Selector Lever Assembly

Remove

1 As required, remove the shift selector assembl y from the floor pan as described in this Section, refer to Remove.

2 As required, separate the lower housing from the base as described in this Section,

refer to Lower Housing Assembly

NOTE

Ensure the locking bolt, trunnion and associated

parts have previously been removed from the

lower end of the selector linkage, refer to

3.2 Selector Linkage and Rod, Except AWD.

This is necessary to provide clearance for the

removal of the selector lever from the base.

3 Remove the outer seal (1) from the selector lever.

Figure 7D4 – 55

4 Remove the selector lever lock ing piece (1) using a

small screwdriver (2) to lever the locking tang free

while pulling on the locking piece with long nosed

pliers (3).

Figure 7D4 – 56

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–36

Page 7D4–36

NOTE

When removing the selector lever assembly:

• While it will be necessary to manoeuvre the

selector lever somewhat, sufficient space is

provided to overcome any need to apply

force for the removal.

• The bush will probably remain in the base.

5 Push the selector lever assembly (1) inwards to

release the inner support pin (2) and bush (3) and then

lift the selector lever from the base (4) to remove it.

Further disassembly of the selector lever is

not recommended as there is a possibility

that, during reinstallation of the roll pin, the

selector lever will be cracked unless

sophisticated jigs are used. For this reason,

the shift lever is only serviced as an

assembly.

Figure 7D4 – 57

Reinstall

1 Inspect the selector lever inner bush (1) for damage,

replace as required. Lubricate the inner bush with a

multi-purpose chassis grease such as NLGI No. 1

Lithium grease or equivale nt.

2 Lubricate the split inner suppor t bush (2) with a multi-

purpose chassis grease such as NLGI No. 1 Lithium

grease or equivalent and re install the bush to the

selector lever pin aligning the split in the bush with the

key on the pin.

3 Align the inner support bush with the aperture in the

base and push it across to fully install the se lector

lever (3) in the base.

Figure 7D4 – 58

4 Using long nosed pliers, reinstall the selector lever

locking piece (1) into the base.

NOTE

An audible click will indicate if the tang on the

locking piece is correctly inserted in the base.

Figure 7D4 – 59

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–37

Page 7D4–37

5 Apply a smear of multi-purpose chassis grease such

as NLGI No. 1 Lithium grease or equivalent to the

outer seal (1) and install it over the selector lever.

6 Reinstall the lower housin g on the base as described

in this Section, refer to Lower Housing Assembly.

7 Reinstall the shift selector assembly as described in

this Section, refer to Reinstall.

Figure 7D4 – 60

Reinstall

1 Clean the mating surfaces of floor pan and inspect the

base seal for damage, replace as required.

2 From inside the vehicle, reinstall the shift selector

assembly (1) to the floor pan.

3 At the rear of the shift selector assembly, reconnect

the harness connector (2) to the selector patch

harness (3).

4 Raise the vehicle and suppor t in a safe manner,

refer to Section 0A General Information for the location

of support points.

5 From underneath the vehicle, install the four nuts (4)

attaching the shift selector assembly to the floor pan,

tighten to the correct torque specification.

Selector base attaching nut

torque specification..................................12.0 –18.0 Nm

6 Reconnect the selector rod and trunni on to the

selector linkage, refer to 3.2 Selector Linkage and

Rod, Except AWD.

7 Reinstall the following components, refer to

Section 1A3 Instrument Panel and Co nsole:

a floor console assembly,

b lower extension side trim panels and

c floor console cover.

Figure 7D4 – 61

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–38

Page 7D4–38

3.6 Shift Selector Assembly, AWD

LT Section No. — 04–190

Remove

1 Remove the following components, refer to Section 1A3 Instrument Panel and Console:

a floor console cover,

b lower extension side trim panels and

c floor console assembly.

2 At the rear of the shift selector assembly, disconn ect

the harness connector (1) from the selector patch

harness (2).

NOTE

The shift selector assembly needs to be

disconnected and detached from the floor pan

only to service the base and selector lever. The

lower housing and associated components can

be separated from the base for servicing.

3 From inside the vehicle, disconn ect the transmission

selector cable from the selector link age and the base,

refer to 3.3 Selector Cable Assembly, AWD.

4 Raise the vehicle and suppor t in a safe manner,

refer to Section 0A General Information for the location

of jacking and support points.

5 Remove the following components, refer to

Section 7F Transfer Case and Adaptor Ho using:

a catalytic converter bracket,

b transmission support and

c transfer case support mount.

6 Lower the rear of the transmission and transfer case to

access the nuts attaching the shift selector assembly

to the vehicle floor pan.

Figure 7D4 – 62

7 Remove the nut (1), four places, attaching the shift

selector assembly to the floor pan.

8 Remove the two nuts attaching the selector cable

upper bracket and grommet to the floor pan, forward of

the shift selector base.

NOTE

This is necessary to provide clearance for the

shift selector assembly removal.

9 From inside the vehicle, lift the shift selector assembly

from the floor pan.

Figure 7D4 – 63

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–39

Page 7D4–39

Disassemble

NOTE

There is no serviceable item in the selector lever

assembly or the base, disassembly is restricted

to the lower housing and associated components.

Lower Housing Assembly

Remove

NOTE

The lower housing assembly can be

disassembled without the base being detached

from the floor pan.

1 With the selector lever in the D position, use a suitable

size Torx bit and remove the screw (1) on the forward

side of the lever (2).

NOTE

This is also the recommended reassembly

position.

Figure 7D4 – 64

2 From the rear of the selector base, use a small flat

blade screwdriver (1) to gently prise, through the

hole (2), the locking tab on the patch harness

connector (3) and pull the connector away from its

support on the shift selector base (4).

Figure 7D4 – 65

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–40

Page 7D4–40

3 Using long nosed pliers (1) compress the peg (2), four

places, on the lower housing (3) and separate each

peg from the base (4).

4 Lift the lower housing from the base together with the

switch(s), patch wiring harness, upper cover, boot and

selector knob.

Figure 7D4 – 66

Reinstall

1 Ensure the PRNDL indicator slide, in the lower ho using (1), is at the D position with the red colour showing

opposite the D in the PRNDL lens (2), refer to Figure 7D4 – 67.

2 Ensure the selector lever (3) is in the D position with the pin (4) located as shown.

3 Reinstall the lower housin g assembly over the selector lever, engaging the PRNDL indicator connection (5) with the

selector lever pin (6).

4 Ensure the PRNDL indicator slide has rema ined at the D position.

Figure 7D4 – 67

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–41

Page 7D4–41

5 Align the pin (1), four places, on the lo wer housi ng (2)

with the corresponding hole i n the base (3) and

engage each pin tapping lightly with the heel of the

hand or use long nosed p liers (4) to compress each

pin.

Figure 7D4 – 68

NOTE

If the knob button (4) and spring have not been

removed, some manoeuvring may be necessary

to re-engage the selector lever.

6 Re-engage the selector lever knob (1) with the

selector lever, aligning the control rod with the hole in

the selector knob.

7 Check the engagement of the PRNDL indicator

connection by moving the selector lever. If the

coloured portion (2) does not move with the lever,

separate the lower housing from the base and repeat

procedure steps 1 to 4.

8 Reinstall the selector knob attaching Torx screw (3)

and tighten to the recommended torque spec ification.

Selector knob attaching Torx screw

torque specification.....................................1.0 – 3.0 Nm

9 If required, reinstall the knob button (4) and spring,

push the button down until the two locking tangs are

engaged.

Figure 7D4 – 69

10 Secure the patch harness connector (1) to its

support (2) on the rear of the selector base.

Figure 7D4 – 70

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–42

Page 7D4–42

Patch Harness and Switch

The patch harness and switch removal and reinstallation procedure for AW D vehicles is identical to the procedure for

RWD vehicles, refer to 3.4 Shift Selector Assembly, Except Coupe and AWD.

Upper Cover, Boot and Selector Knob

The upper cover, boot and selector knob removal and reinstallation procedure for AWD vehicles is identical to the

procedure for RWD vehicles, refer to 3.4 Shift Selector As sembly, Except Coupe and AWD.

Reinstall

1 Clean the mating surfaces of floor pan and inspect the

base seal for damage, replace as required.

2 From inside the vehicle, reinstall the shift selector

assembly (1) and the selector cable upper bracket and

grommet (2) to the floor pan.

3 At the rear of the shift selector assembly, reconnect

the harness connector (3) to the selector patch

harness (4).

4 From underneath the vehicle, install the four nuts (5)

attaching the shift selector assembly to the floor pan,

tighten to the correct torque specification.

Selector base attaching nut

torque specification.................................12.0 – 18.0 Nm

5 From underneath the vehicle, install the two nuts (6)

attaching the selector cable u pper bracket and

grommet to the floor pan.

Selector cable upper bracket

to floor pan attaching nut

torque specification.................................12.0 – 18.0 Nm

Figure 7D4 – 71

6 Reinstall the following components, refer to Section 7F Transfer Case and Adaptor Housing:

a transfer case support mount,

b transmission support and

c catalytic converter bracket.

7 From inside the vehicle, reconnect the trans mission selector cable to the selector linkage and the base, adjust the

cable if required, refer to 3.3 Selector Cable Assembly, AWD.

8 Reinstall the following components, refer to Section 1A 3 Instrument Panel and Console:

a floor console assembly,

b lower extension side trim panels and

c floor console cover.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–43

Page 7D4–43

3.7 Neutral Start and Back-up Lamp Switch,

Except AWD

LT Section No. — 04–170

Remove

1 Position the transmission selector lever to the Park position.

2 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

3 Hold the transmission manua l shaft linka ge (1) with an

adjustable wrench and remove the linkage attaching

nut (2).

4 Carefully remove the manual shaft linkage and

selector rod from the transmission manual sh aft (3).

5 Prise the connector position assurance (CPA)

securing pin (4) from the neutral start and back-up

lamp switch (5) taking care not to break the pin in the

process.

6 Disconnect connector (6) from the switch assembly by

pulling down the release bar (7).

NOTE

The connector will automatically disconnect at

the same time the release bar is withdrawn.

7 Remove the two attaching screws (8 and 9) and slide

the switch assembly over the transmission manual

shaft to remove it. Figure 7D4 – 72

Reinstall

1 Slide the neutral start and back-up lam p switch (5) over the transmission manual shaft (3) and reinstall the two

attaching screws (8 and 9), tighten them finger tight until the adjustment process has been completed, refer to

Figure 7D4 – 72.

2 Reinstall the manual sh aft linkage (1) and the attaching nut (2). Hold the linkage with an adjustable wrench and

tighten the nut to the correct torque specification.

Manual shaft linkage attaching nut

torque specification.................................15.0 – 35.0 Nm

3 Reinstall the connector (6) bu t do not reinsert the CPA securing pin (4) at this stage.

4 Check the shift selector linkage operatio n and adjust as required,

refer to 3.2 Selector Linkage and Rod, Except AWD.

5 Check and adjust as required the neutral sta rt and back-up lamp switch as described in this Section, refer to Adjust.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–44

Page 7D4–44

Adjust

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 If required, loosen the neutral start and back-up lamp switch (5) as follows, refer to Figure 7D4 – 72:

a Prise the connector position assurance (CPA) securing pin (4) from the neutral start and back-up lamp

switch (5) taking care not to break the pin in the process.

b Disconnect connector (6) from the switch assembly by pulling down the release bar (7).

NOTE

The connector will automaticall y disconnect at the

same time the release bar is withdr awn.

c Loosen the two screws (8 and 9) attaching the switch and keep them finger tight.

d Reinstall the connector (6) bu t do not reinsert the CPA securing pin at this stage.

3 Rotate the neutral start and back-up lamp switch back a nd forth until a central position is attained and then lightl y

tighten the front screw (8) to prevent the switch from rotating.

Ensure the four wheels are off the ground

before performing the starting test.

4 With the ignition switched to the ON position, check if the engine can only be started in the Park and Neutral shift

selector positions and ensure the back-up lamps illuminate when Reverse is selected. A further minor adjustment

may be required to achieve this state.

NOTE

To gain access to the rear attaching screw (9) it

will be necessary to remove the connector.

5 After the switch has been adjusted, tighten the two attaching screws to the correct torque specification.

Neutral start and back-up lamp switch

attaching screw torque specification.......15.0 – 35.0 Nm

6 Reinstall the connector an d the CPA securing pin.

7 Lower the vehicle to the ground an d re-check the operation of the neutral start and back-up lamp switch. The

vehicle must start only with the shift selector in the Park or Neutral positions and the back-up lamps should only

illuminate when Reverse is selected.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–45

Page 7D4–45

3.8 Neutral Start and Back-up Lamp Switch,

AWD

LT Section No. — 04–170

Remove

1 Position the transmission selector lever to the Park position.

2 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

3 Remove the front propeller shaft, refer to Section 4C2 Front Propeller Shaft and Universal Joints.

4 Using a small flat blade scre wdriver (1), gentl y prise

the selector cable end (2) from the transmission

external manual shaft linkag e (3).

Figure 7D4 – 73

5 Hold the transmission manua l shaft linka ge (1) with an

adjustable wrench and remove the linkage attaching

nut (2).

6 Carefully remove the manual shaft linkage from the

transmission manual shaft (3).

7 Prise the connector position assurance (CPA)

securing pin (4) from the neutral start and back-up

lamp switch (5) taking care not to break the pin in the

process.

8 Disconnect connector (6) from the switch assembly by

pulling down the release bar (7).

NOTE

The connector will automatically disconnect at

the same time the release bar is withdrawn.

9 Remove the two attaching screws (8 and 9) and slide

the switch assembly over the transmission manual

shaft to remove it. Figure 7D4 – 74

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–46

Page 7D4–46

Reinstall

1 Slide the neutral start and back-up lam p switch (5) over the transmission manual shaft (3) and reinstall the two

attaching screws (8 and 9), tighten them finger tight until the adjustment process has been comp leted, refer to

Figure 7D4 – 74.

2 Reinstall the manual sh aft linkage (1) and the attaching nut (2). Hold the linkage with an adjustable wrench and

tighten the nut to the correct torque specification.

Manual shaft linkage attaching nut

torque specification.................................15.0 – 35.0 Nm

3 Reinstall the connector (6) bu t do not reinsert the CPA securing pin (4) at this stage.

4 Reinstall the shift selector cable (10) to the manual shaft linkage, check and adjust as required the cable

adjustment, refer to 3.3 Selector Cable Assembly, AWD.

5 Check and adjust as required the neutral sta rt and back-up lamp switch as described in this Section, refer to Adjust.

Adjust

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 If required, loosen the neutral start and back-up lamp switch (5) as follows, refer to Figure 7D4 – 74:

a Remove the front propeller shaft, refer to Section 4C2 Front Propeller Shaft and Universal Joints.

b Prise the Connector Position Assurance (CP A) securing pin (4) from the neutral start and back-up lamp

switch (5) taking care not to break the pin in the process.

c Disconnect connector (6) from the switch assembly by pulling down the release bar (7).

NOTE

The connector will automaticall y disconnect at the

same time the release bar is withdr awn.

d Loosen the two screws (8 and 9) attaching th e switch and keep them finger tight.

e Reinstall the connector (6) bu t do not reinsert the CPA securing pin at this stage.

3 Rotate the neutral start and back-up lamp switch back a nd forth until a central position is attained and then lightl y

tighten the front screw (8) to prevent the switch from rotating.

Ensure the vehicle four wheels are off the

ground before performing the starting test.

4 With the ignition switched to the ON position, check if the engine can only be started in the Park and Neutral shift

selector positions and ensure the back-up lamps illuminate when Reverse is selected. A further minor adjustment

may be required to achieve this state.

NOTE

To gain access to the rear attaching screw (9) it

is necessary to remove the connector.

5 After the switch has been adjusted, tighten the two attaching screws to the correct torque specification.

Neutral start and back-up lamp switch

attaching screw torque specification.......15.0 – 35.0 Nm

6 Reinstall the connector an d the CPA securing pin.

7 Reinstall the front propeller shaft, refer to Section 4C2 Front Propeller Shaft and Universal Joints.

8 Lower the vehicle to the ground an d re-check the operation of the neutral start and back-up lamp switch. The

vehicle must start only with the shift selector in the Park or Neutral positions and the back-up lamps should only

illuminate when Reverse is selected.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–47

Page 7D4–47

3.9 Vehicle Speed Sensor, Except AWD

LT Section No. — 04–200

Remove

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 Disconnect connector (1) from the vehicle speed

sensor (2).

3 Remove the bolt (3) attaching the speed sensor to the

transmission extension housing.

4 With a pulling and turning motion, remove the speed

sensor and O-ring seal (4) from the transmission

extension hous ing, discard the O-ring.

Figure 7D4 – 75

Reinstall

1 Lubricate a new O-ring seal with petroleum jell y and install it to the vehicle speed sensor.

2 Reinstall the speed sensor to the transmission extension housing.

3 Reinstall the attachin g bolt and tighten to the correct torque specification.

Vehicle speed sensor attachin g bolt

torque specification..................................11.0 - 14.0 Nm

4 Reconnect the connector to the speed sensor.

5 Lower the vehicle to the ground.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–48

Page 7D4–48

3.10 Vehicle Speed Sensor, AWD

LT Section No. — 04–200

Remove

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 Remove the following components, refer to Section 7F Transfer Case and Adaptor Housing:

a catalytic converter and adaptor housing bracket,

b transmission support and

c transfer case rear mounting bracket.

NOTE

If necessary, lower the transfer case to access

the vehicle speed sensor attached to the

transmission adaptor housing.

3 Disconnect connector (1) from the vehicle speed

sensor (2).

4 Remove the bolt (3) attaching the speed sensor.

5 With a pulling and turning motion remove the speed

sensor and O-ring seal (4) from the transmission

adaptor housing (5), discard the O-ring.

Figure 7D4 – 76

Reinstall

1 Lubricate a new O-ring seal with petroleum jell y and install it to the vehicle speed sensor.

2 Position the speed sensor on the transmission adaptor housing.

3 Attach the speed sensor with the bolt and tighten to the correct torque specification.

Vehicle speed sensor attachin g bolt

torque specification.................................11.0 – 14.0 Nm

4 Reconnect the connector to the speed sensor.

5 Reinstall the following components, refer to Section 7F Transfer Case and Adaptor Housing:

a transfer case rear mounting bracket,

b transmission support and

c catalytic converter and adaptor housing bracket.

6 Lower the vehicle to the ground.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–49

Page 7D4–49

3.11 Manual Shaft Oil Seal

LT Section No. —

Replace

NOTE

If the special tool No. AU583 is not available, the

seal can still be replaced but it requires the

removal of the manual shaft from the

transmission case. Refer to Section 7D5

Automatic Transmission – 4L65E – Unit Repair.

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 Remove the neutral start and back-up lamp switch, refer to:

• 3.7 Neutral Start and Back-up Lamp Switch, Except AW D, or

• 3.8 Neutral Start and Back-up Lamp Switch, AW D.

3 Assemble the seal remover, Tool No. AU583-3 (1) b y

installing the remover nut, Tool No. AU583-4 (2) with

its threaded inner diameter closest to the hexagonal

head of the seal remover tool. Install the nut up to the

hexagonal hea d.

4 Install the assembled seal remover tool over the

manual shaft (3) engaging the tapered threa d end (4)

into the seal.

Do not over tighten the seal remover tool in

the seal.

5 Rotate the hexagonal hea d of the seal remover tool

clockwise, until the thread grips the steel shell of the

seal.

Figure 7D4 – 77

6 While holding the hexagonal head of the seal remover

tool (1) rotate the remover nut (2) clockwise, until it

contacts the transmission case.

7 Continue rotating the remov er nut until the seal is

pulled into the remover nut cavit y.

8 Remove and discard the seal.

Figure 7D4 – 78

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–50

Page 7D4–50

9 Install the seal protector, Tool No. AU583-1 (1) into

one of the two plastic seal installers, Tool No.

AU583-2 (2).

NOTE

Two plastic seal installers are required because

of the restricted space between the end of the

manual shaft and the floor pan.

10 Lubricate the lip of a new seal (3) with clean automatic

transmission fluid and install it over the seal protector

sleeve, with the steel casing facing the insta ller tool.

11 Install the seal protector with the new seal and installer

tool over the manual shaft (4) and up to the

transmission case.

If the seal protector sleeve jams on the

manual shaft, the flats on the shaft locating

the selector lever will be burred. Use a fine

file to remove any burrs and then proceed.

12 Fit the second plastic seal installer over the manual

shaft until it seats against the first installer.

13 Install the manual shaft linkage attaching nut (5) and

tighten it to drive the seal in position into the

transmission case.

14 Remove the seal installer and protector tools from the

manual shaft.

Figure 7D4 – 79

15 Reinstall the neutral start and back-up lamp switch, refer to:

• 3.7 Neutral Start and Back-up Lamp Switch, Except AW D, or

• 3.8 Neutral Start and Back-up Lamp Switch, AW D.

16 Lower the vehicle to the ground an d as required, check and top up the automatic transmission fluid lev el, refer to

2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–51

Page 7D4–51

3.12 Transmission Support and Mount,

Except Coupe and AWD

LT Section No. — 04–020

Remove

1 Raise the vehicle and suppor t in a safe manner,

refer to Section 0A General Information for the location

of support points.

2 Using a felt tipped pen or similar, mark the positio n of

the transmission support (1) to the under body sid e

rails

NOTE

This will assist in aligning the transmission

support on reinstallation.

3 Support the transmission with a Jack, do not plac e the

support underneath the extension housing or the oil

pan.

4 Remove the two nuts (2) attaching the transmission

mount to the support, make note of the through holes

location on the support.

5 Remove the four bolts (3) attaching the transmission

support to the under body side rails and remove the

support.

6 If required, remove the two bolts (4) attaching the

transmission mount (5) to the ext ension housing and

remove the mount.

Figure 7D4 – 80

Reinstall

1 If required, reinstall the transmission mount (5 ) onto the extension housing with the two attaching bolts (4) finger

tight, refer to Figure 7D4 – 80.

NOTE

If there is no locating marks, align all holes

centrally over the studs/bolts in the following

procedure.

2 Position the transmission support (1), aligning it with the marks done during remova l on the under body side rails.

3 Ensure the studs of the transmission mount are fitted

through the rear holes (1) in the support, or as noted

during removal.

Figure 7D4 – 81

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–52

Page 7D4–52

4 Reinstall the support four attachin g bolts (3) finger tight, refer to Figure 7D4 – 80.

5 As required, tighten the transmission mount two attaching bolts (4) to the correct torque specification.

Transmission mount attaching

bolt torque specification..........................50.0 – 65.0 Nm

6 Tighten the transmission support four attaching bolts (3) to the correct torque specification.

Transmission support attaching

bolt torque specification..........................50.0 – 65.0 Nm

7 Reinstall and tighten the transmission mount two attaching nuts (2) to the correct torque specific ation.

Transmission mount attaching

nut torque specification...........................20.0 – 30.0 Nm

8 Lower the vehicle to the ground.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–53

Page 7D4–53

3.13 Transmission Support and Mount,

Coupe

LT Section No. — 04–020

Remove

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 Using a felt tipped pen or similar, mark the positio n of

the transmission support (1) to the under body sid e

rails

NOTE

This will assist in aligning the transmission

support on reinstallation.

3 Support the transmission with a Jack, do not plac e the

support underneath the extension housing or the oil

pan.

4 Remove the two nuts (2) attaching the transmission

mount to the support, make note of the through holes

location on the support.

5 Remove the four bolts (3) attaching the transmission

support to the under body side rails and remove the

support.

6 If required, remove the two bolts (4) attaching the

transmission mount (5) to the ext ension housing and

remove the mount.

Figure 7D4 – 82

Reinstall

1 If required, reinstall the transmission mount (5 ) onto the extension housing with the two attaching bolts (4) finger

tight, refer to Figure 7D4 – 82.

NOTE

If there is no locating marks, align all holes

centrally over the studs/bolts in the following

procedure.

2 Position the transmission support (1), aligning it with the marks done during remova l on the under body side rails.

3 Ensure the studs of the transmission mount are fitted

through the rear holes (1) in the support, or as noted

during removal.

Figure 7D4 – 83

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–54

Page 7D4–54

4 Reinstall the support four attachin g bolts (3) finger tight, refer to Figure 7D4 – 82.

5 As required, tighten the transmission mount two attaching bolts (4) to the correct torque specification.

Transmission mount attaching

bolt torque specification..........................50.0 – 65.0 Nm

6 Tighten the transmission support four attaching bolts (3) to the correct torque specification.

Transmission support attaching

bolt torque specification..........................50.0 – 65.0 Nm

7 Reinstall and tighten the transmission mount two attaching nuts (2) to the correct torque specific ation.

Transmission mount attaching

nut torque specification...........................20.0 – 30.0 Nm

8 Lower the vehicle to the ground.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–55

Page 7D4–55

3.14 Extension Housing and Rear Bush,

Except AWD

LT Section No. — 04–200

Remove

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 As required, remove the following c ompo ne nts:

a Exhaust system assembly, refer to Section 8B Exhaust System.

b Rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

c Transmission support and mo unt assembly,

refer to 3.12 Transmission Support and Mo unt, Except Coupe and AWD.

d Vehicle speed sensor, refer to 3.9 Vehicle S peed Sensor, Except AWD.

3 Remove the bolt (1), six places, attaching the

extension hous ing (2) to the transmission case.

4 Remove the extension housin g and seal (3) from the

rear of the transmission case, discard the seal.

Figure 7D4 – 84

Take care not to scratch the machined seal

recess in the extension housing as

transmission fluid may weep past the outer

diameter of the installed seal.

5 If the extension housing rear bush is to be re placed,

remove the oil seal (1) from the extension housing (2),

using a suitable removing tool such as Tool No. E308

and discard the seal.

Figure 7D4 – 85

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–56

Page 7D4–56

NOTE

Before removal, take note of the orientation of

the split in the bush to assist in the replacement

process.

6 If required, using the bush remover, Tool

No. J23062-14 (1) and driver handle, Tool

No. J8092 (2), press the bush (3) out of the extensio n

housing (4) and discar d.

Figure 7D4 – 86

7 Lubricate the outside of a ne w bush with automatic

transmission fluid to reduce the chance of material

pick-up.

8 Ensure the split in the new bush (1) is in the same

orientation as noted previously and Install it into the

extension hous ing (2) using the installer tool, Tool

No. J34196-4 (3) and driver h andle, Tool

No. J8092 (4).

Figure 7D4 – 87

Reinstall

Reinstallation of the extension housing is the reverse of the removal procedure, noting the following:

1 If required, install a new oil seal in the e xtension housing, refer to 3.15 Extension Housing Oil Seal.

2 Lubricate a new seal with clean automatic transmission fluid and fit to the extension housing mounting flange.

3 Tighten the six bolts attaching the extension housing to the correct torque specification.

Extension housing attaching bolt

torque specification.................................42.0 – 48.0 Nm

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–57

Page 7D4–57

3.15 Extension Housing Oil Seal, Except AWD

LT Section No. — 04–200

Replace

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 As required, remove the following c ompo ne nts:

a Exhaust system assembly, refer to Section 8B Exhaust System.

b Rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

3 Place a suitable size drip tray underne ath rear of

transmission.

Take care not to scratch the machined seal

recess in the extension housing as

transmission fluid may weep past the outer

diameter of the installed seal.

4 Using the seal remover, Tool No. E308 (1), pr ise the

oil seal (2) from rear of the extension housing (3) and

discard the seal.

5 Thoroughly cle an around the seal bore in the

extension hous ing and ensure there are no burrs.

Figure 7D4 – 88

6 Use the seal installer, Tool No. J21426 (1) and a soft

faced hammer to tap a new oil seal (2) into place in

the extension housing (3).

7 As required, reinstall the following compo ne nts:

a Rear propeller shaft, refer to Section 4C1 Rear

Propeller Shaft and Universal Joints.

b Exhaust system assembly, refer to

Section 8B Exhaust System.

8 Lower the vehicle to the ground an d check the fluid

level, refer to 2.1 Transmission Fluid.

Figure 7D4 – 89

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–58

Page 7D4–58

3.16 Transmission Support and Adaptor

Housing, AWD

LT Section No. — 04–200

Remove and Reinstall

For service operation of the transmission support and adaptor housing for AWD vehicles,

refer to Section 7F Transfer Case and Adaptor Housing.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–59

Page 7D4–59

3.17 Shift Solenoid Locations

Location and Identification

Legend

1 Transmission Fluid Pressure (TFP) Manual

Valve Position Switch.

2 1 – 2 Shift Valve Solenoid A.

3 2 – 3 Shift Valve Solenoid B.

4 Pressure Control Solenoid (PCS).

5 Torque Converter Clutch Pulse Width Modulated

(TCC PWM) Solenoid.

6 3 – 2 Control Solenoid.

Figure 7D4 – 90

To service the TCC PWM solenoid, refer to 3.19 Control Valve Body Harness.

For further information and service procedures of the shift solenoids, refer to

Section 7D5 Automatic Transmission – 4L65E – Unit Repair.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–60

Page 7D4–60

3.18 1 – 2 Accumulator Assembly

LT Section No. —

Throughout this Section when using

compressed air and cleaning fluids, wear

safety glasses and gloves to avoid personal

injury.

Remove

1 Remove the oil pan and filter, refer to 3.1 Fluid Change and Filter Replacement.

2 Remove the two short bolts (1) and one long bolt (2)

attaching the accumulator cover (3) and rem ove the

cover.

3 Using low pressure compressed air applied to the

drilling in the cover, remove t he 1 – 2 accumulator

piston and seal assembly (4) and the two

springs (5 and 6).

4 Remove the seal from the piston and discard the seal.

Figure 7D4 – 91

Clean and Inspect

1 Clean all components in a commercially available cleaning fluid and blow dry using compressed air.

2 Inspect the springs and ensure they are not distorted or broken, replace as required.

3 Inspect all machined surfaces for damage, wear or burrs.

Reinstall

Reinstallation of the 1 – 2 accumulator assembly is the reverse of the removal procedure , noting the following:

1 Lubricate a new seal with petroleum jelly and install it to the piston. Ensure the piston seal do es not bind in the

piston groove.

2 Tighten the three bolts attaching the acc umul ator cover to the correct torque specification.

1 – 2 Accumulator cover attaching

bolt torque specification.....................................12.0 Nm

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–61

Page 7D4–61

3.19 Control Valve Body Harness

LT Section No. —

Remove

1 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

2 As required, remove the oil pan and filter, refer to 3.1 Fluid Change and Filter Replacement.

3 Disconnect the control valve body har ness connectors

from all electrical components except the torque

converter clutch (TCC) solenoid, which is hard wired.

Connectors identification:

• Transmission Fluid Pressure (TFP) Manual

Valve Position Switch (1)

• 1 – 2 Shift Valve Solenoid A (2)

• 2 – 3 Shift Valve Solenoid B (3)

• Pressure Control Solenoid (PCS) (4)

• Torque Converter Clutch Pulse Width Modulated

(TCC PWM) Solenoid (5)

• 3 – 2 Control Solenoid (6).

NOTE

For information and service procedures of the

shift solenoids, refer to Section 7D5 Automatic

Transmission – 4L65E – Unit Repair. Figure 7D4 – 92

To prevent personal injury, wear safety

glasses when removing the clip.

NOTE

Note the following when remo ving the solenoid:

• If required, rotate the solenoid until the flat

part of the clip becomes visible.

• The removal is only necessary to access the

TCC solenoid attaching bolts.

4 Using a hooked piece of wire or a small flat blade

screwdriver, remove the clip (1) retaining the

TCC PWM solenoid (2).

5 With a twisting and pulling motion remove the

TCC PWM solenoid from the control valve body,

remove and discard the O-ring.

Figure 7D4 – 93

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–62

Page 7D4–62

6 Remove the two bolts (1) attaching the TCC solenoid

assembly (2) to the control valve body.

Figure 7D4 – 94

7 Withdraw the TCC solenoid as sembly (1) from the

control valve body (oil pump hous ing), remove and

discard the O-ring.

8 Lower the harness (2) and TCC solenoid, allow it to

hang from the pass-thru connector (3).

9 Remove the control valve bod y, refer to

3.20 Control Valve Body.

NOTE

This is necessary to provide clearance for the

pass-thru connector to be removed.

Figure 7D4 – 95

10 Lower the transmission to provide clearance between

the floor pan and the pass-thru connector located at

the right-hand rear of the transmission case.

11 Install the connector release, Tool No. 700-4208 (1)

over the pass-thru connector and us e hand force to

push the tool down compressing the four retainin g

tangs on the connector.

12 Pull the pass-thru connector free from the

transmission case and remove the control v alve b od y

harness and TCC solenoid assembly from the

transmission.

13 Remove the O-ring from the pass-thru connector and

discard.

Figure 7D4 – 96

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–63

Page 7D4–63

Reinstall

1 Lubricate a new O-ring with petroleum jelly and fit it to the pass-thru connector.

2 Reinstall the pass-thru connector up through the hole in the transmission case pushing it in until all four r etain ing

tangs have emerged on the outside of the transmission case. Gently pull on the connector to check if engagement

is secured.

3 Reinstall the control valve body, refer to 3.20 Control Valv e Body.

4 Lubricate a new O-ring with petroleum jelly and fit it to

the TCC solenoid (2).

5 Reinstall the TCC solenoid assembly in the control

valve body , tighten the two attaching bo lts (1) to the

correct torque specification.

TCC solenoid attaching bolt

torque specification............................................12.0 Nm

Figure 7D4 – 97

6 Lubricate a new O-ring with petroleum jelly and fit it to

the TCC PWM solenoid (2).

7 Reinstall the TCC PWM solenoid in the control valve

body and secure it with the retaining clip (1).

Figure 7D4 – 98

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–64

Page 7D4–64

8 Reconnect the control valve body harness connectors.

Connectors identification:

• Transmission Fluid Pressure (TFP) Manual

Valve Position Switch (1)

• 1 – 2 Shift Valve Solenoid A (2)

• 2 – 3 Shift Valve Solenoid B (3)

• Pressure Control Solenoid (PCS) (4)

• Torque Converter Clutch Pulse Width Modulated

(TCC PWM) Solenoid (5)

• 3 – 2 Control Solenoid (6).

Figure 7D4 – 99

9 Secure the harness frame to the control valv e body,

place the tab between the valve body and pressure

switch in location (1) and press the harness frame in

position on bolt bosses (2 and 3).

Figure 7D4 – 100

10 Reinstall the oil pan and filter and fill the transmission with the recommended automatic transmission fluid, refer to

3.1 Fluid Change and Filter Replacement.

11 Lower vehicle to the ground.

12 Road test until the transmission has reached operating temperature. Re-check the fluid l evel and for any fluid leaks

from the oil pan area, refer to 2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–65

Page 7D4–65

3.20 Control Valve Body

LT Section No. —

Remove

1 Partially remove the control v alve b ody harness until it hangs from the pass-thru connector, refer to

3.19 Control Valve Body Harness.

2 Remove the three long bolts (1) and the two short

bolts (2) attaching the transmission fluid pressure

(TFP) manual valve position switch assembly (3),

remove the switch and discard the shield (4).

3 Remove the attaching bolt (5) and the manual detent

spring (6).

Figure 7D4 – 101

In the following procedure support the

control valve body before removing the last

bolt.

NOTE

The removal may be more manageable by

removing the bolts in a spiral pattern starting

from the outside, removing the centre bolt last.

4 Remove the fourteen remaining bolts (1) attaching the

control valve body.

Figure 7D4 – 102

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–66

Page 7D4–66

Keep the control valve body level when

lowering it to prevent the loss of the

checkballs located in the body passages.

5 Carefully lower the control valve body (1) from the

transmission case. As the valve body is being lowered,

rotate it slightly to disconnect the manual valve link (2)

from the manual valve (3) and remove the control

valve body.

6 Remove the manual valve link from the inner detent

lever (4).

Figure 7D4 – 103

Disassemble, Clean, Inspect and Reassemble

For these service operations, refer to Section 7D5 Automatic Transmission – 4L65E – Unit Repair.

Reinstall

Different bolt sizes are used to attach the control valve body and components, Figure 7D4 – 104 shows the location of

the attachment bolts with the letters referring to their dimensions.

NOTE

For clarity, the control valve body harness is not

shown in the illustration.

Figure 7D4 – 104

Legend

1 Control Valve Body

2 Torque Converter Clutch (TCC) Solenoid

3 Transmission Fluid Pressure (TFP) Manual Valve Position

Switch

4 Manual Detent Spring

5 1 – 2 Accumulator Cover

A Bolt M6 x 1.00 x 65.0

B Bolt M6 x 1.00 x 54.4

C Bolt M6 x 1.00 x 47.5

D Bolt M6 x 1.00 x 18.0

E Bolt M6 x 1.00 x 35.0

F Bolt M6 x 1.25 x 20.0

G Bolt M6 x 1.00 x 12.0

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–67

Page 7D4–67

1 Ensure the spacer plate gasket is in a satisfactory condition, replace as required, refer to

3.21 Spacer Plate, Check Balls, Filter Screens and 3 – 4 Accumulator.

2 If required, reinstall the seven checkballs (1) in the

control valve body securing them with petrole um jelly.

Figure 7D4 – 105

3 Reinstall the manual valve link (1) to the inner detent lever (2), refer to Figure 7D4 – 106.

4 While supporting the control valve b od y (3), rotate it slightly and connect the manual valve link with the manual

valve (4).

Take care not to damage the tw o filter screens

attached to the spacer plate during this

operation.

5 Position the manual valve forward to retai n the li nk connection and carefully raise the valve body into position.

6 Check if the manual valve link is correctly reinstalled in the detent lever and manual valve .

Figure 7D4 – 106

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–68

Page 7D4–68

When reinstalling the bolts throughout this

procedure, ensure to use the correct bolt

dimension in each location.

7 Reinstall one bolt (1) (M6 X 1. 0 X 47.5) hand tight in

the centre of the control valve body to hold it i n place,

at location C as shown.

Figure 7D4 – 107

8 Reinstall hand tight only, the remainder of the fourteen

bolts (1) attaching the control valve body directly.

NOTE

Refer to Figure 7D4 – 104 for each bolt

dimension and corresponding location.

Figure 7D4 – 108

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–69

Page 7D4–69

9 Fit a new shield (1) to the transmission fluid pressure

(TFP) manual valve position switch (2) and reinstall to

the control valve body.

NOTE

Refer to Figure 7D4 – 104 for bolt dimensi on and

corresponding location.

10 Reinstall the three long bolts (3) and the two short

bolts (4) hand tight only.

11 Reinstall the manual d etent sprin g (5) and th e

attaching bolt (6) hand tight only.

Figure 7D4 – 109

The control valve body bolts must be

tightened in an outward spiral starting from

the centre. Failure to follow this pattern may

distort the valve body causing the valves to

jam in their bores.

12 Follow the sequence starting from the centre as shown

by the arrows to tighten the following bolts to the

correct torque specification:

• fourteen bolts (1) attaching the control valve

body,

• five bolts (2) attaching the transmission fluid

pressure (TFP) manual valve position switch and

• one bolt (3) attaching the manual detent spring.

Control valve body attaching bolt

torque specification............................................12.0 Nm

Transmission fluid pressure (TFP)

manual valve position switch attaching

bolt torque specification.....................................12.0 Nm

Manual detent spring attachin g bolt

torque specification............................................23.0 Nm

13 Reinstall the control valve body harness , refer to

3.19 Control Valve Body Harness.

Figure 7D4 – 110

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–70

Page 7D4–70

3.21 Spacer Plate, Check Balls, Filter Screens

and 3 – 4 Accumulator

LT Section No. —

Remove

1 Remove the control valve bod y, refer to 3.20 Control Valve Body.

2 Remove the three attaching bolts (1) and the plate (2)

supporting the spacer plate.

Figure 7D4 – 111

3 While supporting the spacer plate (1), carefully remove

the 1 – 2 accumulator assembly (2), refer to

3.18 1 – 2 Accumulator Assembly.

As the spacer plate and gaskets are lowered

from the transmission, a check ball may

drop. Do not lose the check ball.

4 Remove the two gaskets (3 and 4) and the s pacer

plate from the transmission case.

Figure 7D4 – 112

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–71

Page 7D4–71

5 If required, use snap ring plier s to rotate and pull the

3 – 4 accumulator piston (1) to remove it from the

transmission case. Remove and disc ard the piston

seal.

Figure 7D4 – 113

6 Remove the check-ball (1) if not previously dropped.

Remove the 3rd accumulator check ball assembly (2),

the orifice cup plug (3) and the guide pins (A) from the

transmission case.

Figure 7D4 – 114

Clean and Inspect

To avoid personal injury, wear safety glasses

and gloves when using compressed air and

cleaning fluids.

1 Wash all components in a commercially available cleaning fluid and blow dry using compressed air.

2 Inspect the components for the following:

• piston for porosity,

• ring groove or pin hole damage,

• spring for distortion or damage,

• accumulator bore for wear or damage and

• spacer plate, filter screens and check balls for damage.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–72

Page 7D4–72

Reinstall

1 Lubricate a new seal (1) with petroleum jelly and install

it to the 3 – 4 accumulator piston (2).

2 Reinstall the piston onto the pin (3). The piston side

with the three lugs (4) must face out of the bore.

Figure 7D4 – 115

Ensure the guide pins are fully installed with

no thread visible. Otherwise the spacer plate

gasket could be caught in the thread during

installation, resulting in incorrect alignment.

4 Reinstall the guide pins (A) at the correct locations in

the transmission case.

5 Reinstall the check ball (1) in the transmission case

using a small amount of petroleum je lly to hold it in

place.

6 Reinstall the 3rd accumulator check ball assembly (2)

and the orifice cup plug (3) in the transmission case.

Figure 7D4 – 116

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–73

Page 7D4–73

7 If a new spacer plate (1) is installed, it is necessary to

fit two filter screens (2 and 3) to the spacer plate.

Figure 7D4 – 117

NOTE

When installing the spacer plate locate the

gaskets as follows:

• The gasket (2) marked CA is fitted between

the spacer plate and the transmission case.

• The gasket (3) marked VB is fitted between

the spacer plate and the control valve body.

8 Reinstall the spacer plate (1) wit h the new

gaskets (2 and 3) smeared with petroleum jelly. Hold

the spacer plate in place until the 1 – 2 accumulator is

reinstalled.

9 While supporting the spacer plate, carefully reinstall

the 1 – 2 accumulator assembly (4), refer to

3.18 1 – 2 Accumulator Assembly.

Figure 7D4 – 118

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–74

Page 7D4–74

10 Reinstall the plate (2) supp orting the spacer plate and

tighten the three attaching bolts (1) to the correct

torque specification.

Spacer plate support plate attaching

bolt torque specification.....................................12.0 Nm

11 Reinstall the control valve body, refer to

3.20 Control Valve Body.

12 Reinstall the Oil pan and filter and fill the transmission

with the recommended automatic transmissi on fluid,

refer to 3.1 Fluid Change and Filter Replacement.

13 Lower vehicle to the ground.

14 Road test until the transmission has reached operating

temperature. Re-check the fluid level an d for any fluid

leaks from the oil pan area, refer to

2.1 Transmission Fluid.

Figure 7D4 – 119

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–75

Page 7D4–75

3.22 Filler Tube and Breather Hose

LT Section No. — 04–010

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the battery ground lead.

2 Remove the right-hand dress cover from the engine, refer to Section 6A3 Engine Mechanical – GEN III V8.

3 Release the lock down lever (1) and remove the

transmission fluid level indica tor from the filler tube (2).

Figure 7D4 – 120

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–76

Page 7D4–76

4 Remove the bolt (1) attaching the filler tube (2), to the

rear of the right-hand cylinder head.

5 Using a twisting and pullin g motion, remove the filler

tube from the seal (3) in the transmission case.

6 Lower the filler tube enough to unclip the harness (4)

and breather hose (5) from the filler tube lo wer

bracket.

7 Remove the filler tube from the engine compartment.

8 Remove the filler tube seal from the transmis s ion case

and discard.

9 If the breather hose needs to be replaced pr oceed as

follows:

a Remove the transmission support and lower the

rear of the transmission sufficiently to get access

to the breather hose, refer to:

• 3.12 Transmission Support and Mount,

Except Coupe and AWD or

• 3.13 Transmission Support and Mount,

Coupe or

• 3.16 Transmission Support and Adaptor

Housing, AWD

b Disconnect the breather hose from the T-joint (6)

and the top of the transmission case and

remove.

c If required, remove the bolt (7) attaching the vent

pipe (8) to the floor pan bracket (9), disconnect

from the T-joint and remove the vent pipe.

Figure 7D4 – 121

Reinstall

Reinstallation of the transmis s ion filler tube and/or the breather hose is the reverse of the removal procedure, noting the

following:

1 Smear a new filler tube seal with clean transmission fluid and fit it to the transmission case.

2 Ensure the transmission breather hose and the harness are secured to the filler tube lower bracket.

3 Tighten the bolt attaching the filler tub e br acket to the correct torque specification.

Filler tube bracket attaching bolt

torque specification.................................20.0 – 30.0 Nm

4 If required, tighten the bolt attaching the ve nt pipe to the flo or pan bracket to the correct torque specification.

Vent pipe attaching bolt

torque specification...................................7.5 – 12.0 Nm

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–77

Page 7D4–77

3.23 Transmission Cooler Lines and Hoses

LT Section No. — 04–150

Arrangement

Radiator

Figure 7D4 – 122

Legend

1 Radiator Cooler Inlet Fitting

2 Radiator Cooler Outlet Fitting 3 Radiator Cooler Inlet Hose / Line

4 Radiator Cooler Outlet Hose / Line 5 Cooler Outlet Hose / Line Attaching Clip

To Transmission Fluid Lines

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–78

Page 7D4–78

Fluid Cooler Lines

Figure 7D4 – 123

Legend

1 Transmission Fluid Inlet Line

2 Transmission Fluid Outlet Line

3 Clips – Transmission Fluid Lines

4 Radiator Cooler Outlet Hose / Line

5 Radiator Cooler Inlet Hose / Line

6 Sealing Washers

7 Clamp – Transmission Fluid Lines

8 Attaching Nut

9 Verifier Clip

Radiator Cooler Hoses / Lines

Remove

1 Place a suitable sized drip tra y underneath the connectors.

Mark the flexible hose to the transmission

fluid line prior to removal to ensure correct

orientation during reassembly.

2 While holding the appropriate radiator cooler fitting (1) with a spanner, remove the corresponding cooler hose / line

flare nut (2) with a second spanner, refer to Figure 7D4 – 124.

3 Remove the sealing washer (3) and discard.

4 Plug the radiator cooler and cool er hose / line fittings to prevent fluid loss and contamination.

5 If removing the outlet cooler hose / line (4), unclip it from the radiator fan shroud (5).

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–79

Page 7D4–79

Figure 7D4 – 124

6 Within the engine bay, disc onnect the radiator cooler

hose / line quick-connect fitting (1) usin g the release

tool, Tool No. AU525 (2), as follows:

a Remove the verifier clip (3) from the quick-

connect fitting.

b Open the release tool, place it and close it over

the transmission fluid line (4) to be disconnected,

on the radiator end.

c While pushing the release too l to wards the

quick-connect fitting, pull back the radiator cooler

flexible hose (5) to release the connection.

d Separate the cooler flexible hose from the

transmission fluid line and plug the openings to

prevent fluid loss and/or contamin ation.

7 Remove the radiator cooler hose / line assembly from

the engine compartment.

8 If required, repeat the procedure to remove t he

remaining radiator cooler hose / line. Figure 7D4 – 125

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–80

Page 7D4–80

Reinstall

NOTE

The flexible hose is permanently fitted to the line

leading to the radiator cooler. If the flexible hose

requires replacement a complete hose / line

assembly must be fitted.

1 Remove the plugs from the transmission fluid line and radiator cooler hose / line fittings and wipe all exposed parts

clean.

2 Fit a new sealing washer (1) to the cooler line and

reinstall the line to the radiator cooler fitting (2), do not

tighten at this stage.

3 When reinstalling the outlet cooler hose / line (3), clip it

to the radiator fan shroud (4).

NOTE

The radiator cooler inlet flexible hose quick-

connect fitting (5) and the corresponding

transmission fluid outlet line (6) have each a

white tag (7) to match them on reassembly.

4 Smear the transmission fluid line front fitting with clean

transmission fluid and push the quick-conne c t fitting to

connect the radiator cooler hose / line.

If the verifier clip does not fit, the quick-

connect fitting is not engaged, rectify as

required.

5 As a security check, gently pull on the conn ector to

ensure correct engagement and rei nstall th e verifier

clip (8) to the quick-connect fitting and fluid line.

6 Tighten the flare nut (9) attaching the radiator cooler

hose / line to the correct torque specification.

Radiator cooler hose / line

flare nut torque specification...................20.0 – 25.0 Nm

Figure 7D4 – 126

7 Check the orientation marks done on removal, ensuring there is no fouling of the hose / line and the routeing is

correct, rectify as required.

8 If required, repeat the procedure to reinstall the remaining radiator cooler hose / line.

9 If required, top up the transmission fluid level (cold).

10 Start the engine and check for any fluid leak at the fittings. If a leak is found, stop the engine and rectify the leak.

11 Check and top up the transmission fluid to the correct level as required, refer to 2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–81

Page 7D4–81

Transmission Fluid Lines

Remove

1 Disconnect the radiator cooler hose / line fro m the transmission flu id lines as described in this Section,

refer to Radiator Cooler Hoses / Lines.

2 Remove the transmission support, refer to:

• 3.12 Transmission Support and Mount, Except Coupe and AWD, or

• 3.13 Transmission Support and Mount, Cou pe, or

• 3.16 Transmission Support and Adaptor Ho using, AWD.

3 Carefully lower the rear of the transmission sufficiently to get access to the fluid lines.

4 Place a suitable sized drip tray underneath the transmission.

5 With the rear of the transmission lowered, disconnect

the fluid lines from the transmission, as follows:

a Pull back the verifier disc (1) to release it and

slide it back along the fluid line (2).

b Open the release tool, Tool No J-41623-B (3),

slip it over the fluid line to be disconnected from

the transmission, ahead of the verifier disc.

c Slide the release tool along the fluid line and

engage it with the quick-connect fitting (4).

d While pushing in wards, rotate clockwise the

release tool about one sixth of a turn to release

the spring clip holding the fluid line.

e With the release tool held in this position, pull

back on the fluid line to releas e it.

f Plug all openings to prevent fluid loss and/or

contamination.

g Repeat this process with the remainin g fluid line.

NOTE

If the spring clip and/or O-ring seal in the quick-

connect fitting is damaged during the removal

process, the complete fitting must be replaced.

Figure 7D4 – 127

6 Remove the nut (1) attaching the bracket (2) to the right hand side of the engine and remove the two fluid lines (3)

from the vehicle, refer to Figure 7D4 – 128.

7 As required, separate the two fluid lines by removing the bracket and the two clips (4).

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–82

Page 7D4–82

Figure 7D4 – 128

Reinstall

1 Ensure the spring clip and/or O-ring seal in e ach qu ick-conn ect fitting is not damag ed, replace the complete fitting if

required.

2 As required, fit the bracket (2) and the two clips (4) to the transmission fluid lines, refer to Figure 7D4 – 128.

3 Remove all plugs from the fluid lines and fittings and wipe all exposed parts clean.

4 Position the fluid lines in place and install the nut (1) hand tight.

5 At the transmission end, smear the fluid lines rear fittings with clean automatic transmission fluid and push the

quick-connect fittings together.

If the verifier disc does not clip into place, the

quick-connect fitting is not engaged, rectify

as required.

6 As a security check, push and clip each verification disc into place over the quick-connect fittings. If difficulty is

experienced, repeat the reins tallation process until the verification disc can be clipped into place over the

transmission quick-connect fitting.

7 Ensure the routing of the fluid lines is correct and ther e is no fouling of the fluid lines.

8 Tighten the nut attaching the fluid lines bracket to the correct torque specifications.

Transmission fluid lines bracket

attaching nut torque specification............19.0 – 25.0 Nm

9 Reinstall the transmission su pport, refer to:

• 3.12 Transmission Support and Mount, Except Coupe and AWD, or

• 3.13 Transmission Support and Mount, Cou pe, or

• 3.16 Transmission Support and Adaptor Ho using, AWD.

10 Reconnect the radiator cooler hose / lin e assemblies to the transmission fluid lines as described in this Section,

refer to Radiator Cooler Hoses / Lines.

11 If required, top up the transmission fluid level (cold).

12 Start the engine and check for any fluid leak at the fittings. If a leak is found, stop the engine and rectify the leak.

13 Check and top up the transmission fluid to the correct level as required, refer to 2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–83

Page 7D4–83

3.24 Transmission Assembly – Except AWD

LT Section No. — 04–200

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the battery ground lead.

2 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

3 Disconnect the harness connectors from the following:

a Vehicle speed sensor, refer to 3.9 Vehicle S peed Sensor, Except AWD.

b Neutral start and back-up switch, refer to 3.7 Neutral Start and Back-up L amp Switch, Except AWD.

4 Remove the following components:

a Rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

b Front exhaust assemblies, refer to Section 8B Exhaust System.

c Selector linkage and rod, refer to 3.2 Selector Linkage and Rod, Except AWD.

d Starter motor, refer to Section 6D3-2 Starting System – GEN III V8.

5 From within the starter motor access hole, remove the three bolts (2) attaching the torque converter to the flexplate

and discard, refer to Figure 7D4 – 130.

6 Remove the transmission support, refer to:

• 3.12 Transmission Support and Mount, Except Coupe and AWD, or

• 3.13 Transmission Support and Mount, Cou pe.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–84

Page 7D4–84

Before lowerin g the tran sm ission take c a re of

the following:

• Do not strain the harness and connector

as the connector pins could be

permanently damaged.

• Ensure the inlet manifold does not hit the

firewall.

7 Carefully lower the transmissi on to provide enough

clearance to disconnect the h arness co nnector (1).

Do not wiggle the connector from side to side

during removal as the connector pins could

be permanently damaged.

8 Disconnect the harness connector from the

transmission as follows:

a Roll back the dust boot to access the connector.

b Squeeze the widest side of the connector (A)

inward and pull it directly upward.

Figure 7D4 – 129

9 Remove the screws attaching the harness clips to the right- hand and left-hand sides of the transmission case, refer

to Section 12O Fuses, Relays and Wirin g Ha rnesses.

10 Place a suitable sized drip tray underneath the transmission.

11 Remove the transmission fluid lines, refer to 3.23 Transmission Cooler Lines and Hos es.

12 Disconnect the breather hose from the top of the transmission case.

Support the transmission when removing the

attaching bolts to avoid damage to the torque

converter and flexplate. Do not have the

transmission hangin g.

13 With the transmission supported, using a long socket extension, universal joint and suitable size socket, remove

the bolt (1), eight places, attaching the torque converter ho using to the engine, in the reverse order of the torque

sequence shown in within Figure 7D4 – 130.

The transmission assembly must not be

allowed to rest on its oil pan.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–85

Page 7D4–85

14 Support the transmission assembly on a suitable cradle and secure it. Place a suitable support under the engine oil

pan rail to support the engine after the transmission has been removed.

15 Remove the transmission assembly disengaging the filler tube attached to the engin e.

16 Remove the bolt (3) and torque converter cover (4) on the engine right-hand side, remove the bolt (5) and torque

converter cover (6) on the left-hand side.

17 Install a suitable holding tool to preve nt the torque conv erter from becoming dislodged.

Figure 7D4 – 130

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–86

Page 7D4–86

Reinstall

1 Ensure the transmission and the engine mating surfaces are clean and free of burrs.

2 Lubricate the torque converter spigot (7) with a small amount of high temperature wheel bearing grease, refer to

Figure 7D4 – 130.

3 Install a new filler tube seal into the transmission case.

Support the transmission while installing the

attaching bolts to avoid damage to the torque

converter and flexplate. Do not have the

transmission hangin g.

4 Bring the transmission up to the engine, inserting the filler tube and ensuring the locating dowels completely enter

the torque converter housing.

5 Reconnect the breather hose to the top of the transmission case.

6 With the transmission supported, install th e bolt (1), eight places, attaching the torque converter housing to the

engine and tighten to the correct torque sp ecification following the sequence shown in within Figure 7D4 – 130.

Torque converter housing attaching

bolt torque specification..........................50.0 – 60.0 Nm

7 Push the torque converter forward to meet the flexplate, then hand start three new bolts (2) before tightening to the

correct torque specification.

Torque converter to flexplate attachin g

bolt torque specification..........................60.0 – 70.0 Nm

8 Reinstall the bolt (3) and torque converter cover (4) on the right-hand side and the bolt (5) and torque converter

cover (6) on the left-hand side, tighten the bolts to the correct torque specification.

Torque converter cover attaching

bolt torque specification............................5.0 – 10.0 Nm

9 Reinstall the transmission flu id lines, refer to 3.23 Transmission Cooler Lines and Hoses.

Prior to connecting the harness connector to

the transmission, check that all pins and

seals are in sound condition and the dust

boot is not torn or damaged.

10 Reconnect the transmission harness conn ector to the transmission as follows:

a Push straight down on the connector body until a click is heard.

b Reinstall the dust boot ensuring it is correctl y loc ated.

11 Attach the harness clips to the right-hand and left-hand sides of the transmission case, refer to

Section 12O Fuses, Relays and Wiring Harnesses.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–87

Page 7D4–87

12 Reinstall the following components:

a Starter motor, refer to Section 6D3-2 Starting System – GEN III V8.

b Transmission support, refer to:

• 3.12 Transmission Support and Mount, Except Coupe and AWD, or

• 3.13 Transmission Support and Mount, Cou pe.

c Selector linkage and rod, refer to 3.2 Selector Linkage and Rod, Except AWD.

d Front exhaust assemblies, refer to Section 8B Exhaust System.

e Rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

13 Reconnect the harness connectors to the following:

a Vehicle speed sensor, refer to 3.9 Vehicle S peed Sensor, Except AWD.

b Neutral start and back-up switch, refer to 3.7 Neutral Start and Back-up L amp Switch, Except AWD.

14 Perform a reverse flush of the cooler lines and a flow rate test, refer to 2.2 Reverse Flush and Flow Rate, if either

of the following applies:

• the transmission fluid is contaminated,

• the transmission has been replaced,

• the torque converter has been replaced, or

• the transmission oil pump has been replaced.

15 Lower the vehicle to the ground.

16 If required, top up the transmission fluid level (cold).

17 Reconnect the battery ground lead.

18 Start the engine and check for any fluid leaking at the fitting s. If a leak is found, stop the engine and rectify the leak.

19 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid

leaks, refer to 2.1 Transmission Fluid.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–88

Page 7D4–88

3.25 Transmission Assembly – AWD

LT Section No. — 04–200

Remove

Disconnection of the battery affects certain

vehicle electronic systems. Refer to

Section 00 Warnings, Cautions and Notes

before disconnecting the battery.

1 Disconnect the battery ground lead.

2 Raise the vehicle and suppor t in a safe manner, refer to Section 0A General Information for the location of support

points.

3 Remove the following components:

a Transmission support, refer to Section 7F Transfer Case and Adaptor Housing.

b Rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

c Front exhaust assemblies, refer to Section 8B Exhaust System.

d Front propeller shaft, refer to Section 4C2 Front Propeller Shaft and Universal Joints.

e Selector cable assembly, refer to 3.3 Selector Cable Assembly, AWD.

f Transfer case rear mounting bracket, refer to Section 7F Transfer Case and Adaptor Housing.

g Starter motor, refer to Section 6D3-2 Starting System – V8.

4 Disconnect the harness connectors from the following:

a Vehicle speed sensor, refer to 3.10 Vehicle Speed Sensor, AWD.

b Neutral start and back-up switch, refer to 3.8 Neutral Start and Back-up L amp Switch, AWD.

5 From within the starter motor access hole, remove the three bolts (2) attaching the torque converter to the flexplate

and discard, refer to Figure 7D4 – 132.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–89

Page 7D4–89

Before lowerin g the tran sm ission take c a re of

the following:

• Do not strain the harness and connector

as the connector pins could be

permanently damaged.

• Ensure the inlet manifold does not hit the

firewall.

7 Carefully lower the transmissi on to provide enough

clearance to disconnect the h arness co nnector (1).

Do not wiggle the connector from side to side

during removal as the connector pins could

be permanently damaged.

8 Disconnect the harness connector from the

transmission as follows:

a Roll back the dust boot to access the connector.

b Squeeze the widest side of the connector (A)

inward and pull it directly upward.

Figure 7D4 – 131

9 Remove the harness clips from the right-hand and l eft-hand sides of the transmission case, refer to

Section 12O Fuses, Relays and Wiring Harnesses.

10 Place a suitable sized drip tray underneath the transmission.

11 Remove the transmission fluid lines, refer to 3.23 Transmission Cooler Lines and Hos es.

12 Disconnect the breather hose from the top of the transmission case.

Support the transmission when removing the

attaching bolts to avoid damage to the torque

converter and flexplate. Do not have the

transmission hangin g.

13 With the transmission supported, using a long socket extension, universal joint and suitable size socket, remove

the bolt (1), eight places, attaching the torque converter ho using to the engine, in the reverse order of the torque

sequence shown in within Figure 7D4 – 132.

The transmission assembly must not be

allowed to rest on its oil pan.

Automatic Transmission – 4L65E – On-vehicle Servicing Page 7D4–90

Page 7D4–90

14 Support the transmission assembly on a suitable cradle and secure it. Place a suitable support under the engine oil

pan rail to support the engine after the transmission has been removed.

15 Remove the transmission assembly disengaging the filler tube attached to the engin e.

16 Remove the bolt (3) and torque converter cover (4) on the transmission right-hand side, remove the bolt (5) and

torque converter cover (6) on the transmission left-hand side.

17 Install a suitable holding tool to preve nt the torque conv erter from becoming dislodged.

Figure 7D4 – 132

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Reinstall

1 Ensure the transmission and the engine mating surfaces are clean and free of burrs.

2 Lubricate the torque converter spigot (7) with a small amount of high temperature wheel bearing grease, refer to

Figure 7D4 – 132.

3 Install a new filler tube seal into the transmission case.

Support the transmission while installing the

attaching bolts to avoid damage to the torque

converter and flexplate. Do not have the

transmission hangin g.

4 Bring the transmission up to the engine, inserting the filler tube and ensuring the locating dowels completely enter

the torque converter housing.

5 Reconnect the breather hose to the top of the transmission case.

6 With the transmission supported, install th e bolt (1), eight places, attaching the torque converter housing to the

engine and tighten to the correct torque sp ecification following the sequence shown in within Figure 7D4 – 132.

Torque converter housing attaching

bolt torque specification..........................50.0 – 60.0 Nm

7 Push the torque converter forward to meet the flexplate, then hand start three new bolts (2) before tightening to the

correct torque specification.

Torque converter to flexplate attachin g

bolt torque specification..........................60.0 – 70.0 Nm

8 Reinstall the bolt (3) and torque converter cover (4) on the transmission right-hand side and the bolt (5) and torque

converter cover (6) on the transmission left-hand sid e, tighten the bolts to the correct torque specification.

Torque converter cover attaching

bolt torque specification............................5.0 – 10.0 Nm

9 Reinstall the transmission flu id lines, refer to 3.23 Transmission Cooler Lines and Hoses.

Prior to connecting the harness connector to

the transmission, check that all pins and

seals are in sound condition and the dust

boot is not torn or damaged.

10 Reconnect the transmission harness conn ector to the transmission as follows:

a Push straight down on the connector body until a click is heard.

b Reinstall the dust boot ensuring it is correctl y loc ated.

11 Attach the harness clips to the right-hand and left-hand sides of the transmission case, refer to

Section 12O Fuses, Relays and Wiring Harnesses.

12 Reconnect the harness connectors to the following:

a Vehicle speed sensor, refer to 3.10 Vehicle Speed Sensor, AWD.

b Neutral start and back-up switch, refer to 3.8 Neutral Start and Back-up L amp Switch, AWD.

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13 Reinstall the following components:

a Starter motor, refer to Section 6D3-2 Starting System – V8.

b Transfer case rear mounting bracket, refer to Section 7F Transfer Case and Adaptor Housing.

c Selector cable assembly, refer to 3.3 Selector Cable Assembly, AWD.

d Front propeller shaft, refer to Section 4C2 Front Propeller Shaft and Universal Joints.

e Front exhaust assemblies, refer to Section 8B Exhaust System.

f Rear propeller shaft, refer to Section 4C1 Rear Propeller Shaft and Universal Joints.

g Transmission support, refer to Section 7F Transfer Case and Adaptor Housing.

14 Perform a reverse flush of the cooler lines and a flow rate test, refer to 2.2 Reverse Flush and Flow Rate, if either

of the following applies:

• the transmission fluid is contaminated,

• the transmission has been replaced,

• the torque converter has been replaced, or

• the transmission oil pump has been replaced.

15 Lower the vehicle to the ground.

16 If required, top up the transmission fluid level (cold).

17 Reconnect the battery ground lead.

18 Start the engine and check for any fluid leaking at the fitting s. If a leak is found, stop the engine and rectify the leak.

19 Road test until the transmission has reached operating temperature. Re-check the fluid level and for any fluid

leaks, refer to 2.1 Transmission Fluid.

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4 Specifications

For all 4L65E hydra-matic automatic transmission specifications, refer to

Section 7D1 Automatic transmission – 4L6 5E – General Information.

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Page 7D4–94

5 Torque Wrench Specifications

For a complete listing of all torque wrench s pecifications for the 4L65E hydra-matic automatic transmission, refer to

Section 7D1 Automatic transmission – 4L6 5E – General Information.

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Page 7D4–95

6 Special Tools

For a complete listing of all the special tools used for servicing the 4L65E hydra-matic automatic transmission, refer to

Section 7D1 Automatic transmission – 4L6 5E – General Information.