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    1995 GMC Truck Jimmy 4WD 4.3L CPI 6cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

    Transmission Removal & Installation

    Print

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the transmission.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Shift cable, control lever and the bracket
       
      Exhaust pipes
       
      Parking brake cables
       
      Driveshaft, matchmark for reassembly
       
      Transfer case, if equipped
       
      Transmission to engine braces (vehicles equipped with diesel engines have only 1 brace)
       
      Wiring harness at the transmission
       

    6.  
    7. Support the transmission with a transmission jack.

      Nut securing the transmission mount to the cross member
       

    8.  
    9. Position a transmission jack or equivalent, under the transmission for support.
      NOTE
      Mark position of crossmember when removing to prevent incorrect installation. The tapered surface should face the rear.



      Crossmember. Visually inspect to see if other equipment, brackets or lines, must be removed to permit removal of transmission.
       

    10.  
    11. Perform the following:
      1. Step 1: Remove the torque converter inspection cover.
      2.  
      3. Step 2: Mark the alignment of the torque converter to the flexplate.
      4.  
      5. Step 3: Remove the torque converter to flexplate bolts. Remove the dipstick tube and seal from the transmission. Plug the opening to avoid contamination.
      6.  
      7. Step 4: Disconnect both transmission lines at the transmission and plug them to avoid contamination and leakage.
      8.  
      9. Step 5: Position a J 21366 converter holding strap onto the transmission/torque converter to keep the torque converter from sliding off of the transmission turbine shaft.
        NOTE
        The use of guide pins will not only support the transmission but will prevent damage to the clutch disc. Guide pins can be made by using 2 bolts, the same as those just removed only longer, and cutting off the heads. Make an adjustment slot.

      10.  

    12.  
    13. Remove the remaining bolts and slide transmission straight back from engine. Use care to keep the transmission drive gear straight in line with clutch disc hub.
    14.  
    15. Remove or disconnect the following:
      NOTE
      Ensure that the engine is supported with a jack stand before detaching the transmission from the engine.



      Wiring, clips, tubes and brackets etc., which would interfere with the removal of the transmission
       



      Transmission from the engine
       

    16.  
    17. Carefully lower the transmission using the transmission jack.
    18.  

    To install:

    1. Check the area behind the torque converter for leaks. Replace the front seal, if required.
    2.  
    3. It is good practice to examine the area around the rear crankshaft seal, checking for leaks. If necessary, remove the flexplate and replace the seal.
    4.  
    5. Inspect the flexplate ring gear teeth. If damaged, replace the flexplate.
    6.  
    7. Perform the following steps:
      1. Step 1: With tool J 21366 or equivalent, torque converter holding strap in place, raise the transmission into position with a transmission jack.
      2.  
      3. Step 2: Remove the torque converter holding strap and slide the transmission into place. Slide the transmission straight onto the locating pins while lining up the marks on the flexplate and the torque converter. Be sure the transmission is fully seated against the rear of the engine block and the locating pins are completely engaged.
        WARNING
        DO NOT attempt to draw the transmission to the block with the mounting bolts. If the transmission is not properly seated, the bolts will break the transmission case.


        NOTE
        The torque converter must be flush with the flexplate and rotate freely by hand.

      4.  

    8.  
    9. When satisfied that the transmission is properly seated, install and tighten the transmission-to-engine bolts and/or studs to 34 ft. lbs. (47 Nm).
    10.  
    11. Perform the following steps:
      1. Step 1: Install the dipstick tube and seal.
      2.  
      3. Step 2: Check the alignment marks on the torque converter and flexplate to be sure that they are properly aligned. Install the torque converter bolts. Finger-tighten the bolts to ensure proper converter seating. When the converter is properly seated, tighten the bolts to 46 ft. lbs. (63 Nm).
      4.  
      5. Step 3: Install the torque converter cover. Tighten the retaining bolts to 89 inch lbs. (10 Nm).
      6.  

    12.  
    13. Install or connect the following:

      Wiring, clips, tubes and brackets etc
       
      Transmission cooling lines
       
      Shifter cable
       
      Starter
       
      Exhaust pipes
       
      Transmission crossmember. Torque the bolts to 56 ft. lbs. (77 Nm).
       
      Transmission mount on the transmission. Torque the bolts to 35 ft. lbs. (47 Nm).
       
      Nut and washer that secure the transmission mount to the crossmember. Torque the nut to 38 ft. lbs. (52 Nm).
       
      Transmission to engine brace(s) Torque the bolts to 41 ft. lbs. (55 Nm) for gasoline engines and to 51 ft. lbs. (70 Nm) for diesel engines.
       
      Transfer case, if equipped
       

    14.  
    15. Remove the transmission jack and engine support stands.

      Driveshaft
       
      Shifter lever and boot, on manual transmissions
       
      Negative battery cable
       

    16.  
    17. Refill the transmission with fluid.
    18.  
    19. Road test the vehicle and test for proper operation. Check for leaks.
    20.  

    4l60-E Transmission



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       
      Plug the oil level indicator tube opening in the transmission.
       

    4.  
    5. Remove or disconnect the following:

      Shift cable end from the transmission shift lever ball stud
       
      Front driveshaft, if equipped with a transfer case
       
      Rear driveshaft.
       

    6.  
    7. Plug the transmission oil cooler line connectors in the transmission case.

      Starter motor
       

    8.  
    9. Support the transmission with a transmission jack.

      Torque converter access plug

      Click image to see an enlarged view

      Fig. 2000-01 4L60E removal

       
      Flywheel-to-torque converter bolts
       
      Two bolts and nut securing the transmission rear mount to the transmission
       
      Two bolts securing the heat shield to the transmission
       
      Transmission vent hose, fuel lines, and the wiring harness from the transmission
       
      Stud and the bolt securing the transmission to the engine
       
      Six studs and bolt securing the transmission to the engine. Install tool J21366 onto the transmission bell housing to retain the torque converter. Pull the transmission straight back.
       
      Transmission from the vehicle
       

    10.  
    11. Flush the transmission oil cooler and cooling lines when you remove the transmission.
    12.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      Six studs and one bolt securing the transmission to the engine. Tighten the studs and the bolt to 37 ft. lbs. (50 Nm).
       
      Stud and bolt securing the transmission to the engine. Tighten the stud and the bolt to 37 ft. lbs. (50 Nm).
       
      Flywheel-to-torque converter bolts
       
      Torque converter access plug
       
      Transmission vent hose, fuel lines, and the wiring harness to the transmission
       
      Two bolts securing the heat shield to the transmission. Tighten the bolts to 13 ft. lbs. (17 Nm).
       
      Two bolts and nut securing the transmission rear mount to the transmission. Tighten the bolts and nut to 18 ft. lbs. (25 Nm).
       

    10.  
    11. Remove the transmission jack from the transmission.
    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Install or connect the following:

      Transmission oil cooler lines to the transmission
       
      Front driveshaft, if equipped with a transfer case
       
      Rear driveshaft
       
      Shift cable end to the transmission shift lever ball stud
       

    16.  
    17. Unplug the oil level indicator tube opening in the transmission.
    18.  
    19. Install the transmission oil level indicator tube and seal to the transmission.
    20.  
    21. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    22.  
    23. Lower the vehicle.
    24.  

    4l60e & 4l65-E Transmissions



    1. Remove or disconnect the following:
      NOTE
      Plug the oil level indicator tube opening in the transmission.



      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       



      Shift cable end from the transmission shift lever ball stud
       
      Front propeller shaft, if 4WD
       
      Rear propeller shaft.
       

    2.  
    3. Plug the transmission oil cooler line connectors in the transmission case.
    4.  
    5. Remove or disconnect the following:

      Starter motor
       

    6.  
    7. Support the transmission with a transmission jack.
    8.  
    9. Remove or disconnect the following:

      Click image to see an enlarged view

      Fig. 4L60E removal-Silverado shown



      Torque converter access plug
       
      Flywheel-to-torque converter bolts
       
      Transmission rear mount-to-transmission bolts and nut
       
      Heat shield-to-transmission bolts
       
      Transmission vent hose from the transmission
       
      Fuel lines from the transmission
       
      Wiring harness from the transmission
       
      Transmission-to-engine stud and bolt
       
      Six studs and bolt securing the transmission to the engine.
       

    10.  
    11. Install tool J21366 onto the transmission bell housing to retain the torque converter. Pull the transmission straight back.
    12.  
    13. The transmission from the vehicle
    14.  
    15. Flush the transmission oil cooler and cooling lines.
    16.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      Studs and bolt securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Flywheel to torque converter bolts
       
      Torque converter access plug
       
      Transmission vent hose to the transmission
       
      Fuel lines to the transmission
       
      Wiring harness to the transmission.
       
      Heat shield-to-transmission bolts and tighten to 13 ft. lbs. (17 Nm)
       
      Transmission rear mount-to-transmission bolt and nut and tighten to 18 ft. lbs. (25 Nm)
       

    10.  
    11. Remove the transmission jack from the transmission.
    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Install or connect the following:

      Transmission oil cooler lines
       
      Front propeller shaft, if equipped
       
      Rear propeller shaft
       
      Shift cable end to the transmission shift lever ball stud
       

    16.  
    17. Unplug the oil level indicator tube opening in the transmission.
    18.  
    19. Install the transmission oil level indicator tube and seal to the transmission.
    20.  
    21. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    22.  
    23. Lower the vehicle.
    24.  

    1. Drain the transmission fluid.
    2.  
    3. Remove the driveshaft.
    4.  
    5. Support the transmission with a transmission jack.
    6.  
    7. Remove the transmission mount nuts.
    8.  
    9. Remove the transmission support bolts/nuts.
    10.  
    11. Raise the transmission slightly and remove the transmission support from the vehicle.
    12.  
    13. Remove the exhaust pipe.
    14.  
    15. Remove the starter motor.
    16.  
    17. Remove the transfer case, if equipped.
    18.  
    19. Remove the transmission mount bolts and mount.
    20.  
    21. Ensure the transmission manual shaft is positioned in mechanical park.
    22.  
    23. Remove the retainer that secures the cable to the bracket.
    24.  
    25. Remove the range selector cable end from the transmission range selector lever ball stud.
    26.  
    27. Depress the tangs and remove the cable from the bracket.
    28.  
    29. Remove the exhaust hanger bracket bolts and bracket.
    30.  
    31. Remove the harness clip from the fuel line bracket.
    32.  
    33. Disconnect the park/neutral position (PNP) switch electrical connectors.
    34.  
    35. Disconnect the main electrical connector.
    36.  
    37. Disconnect the vehicle speed sensor (VSS) electrical connector.
    38.  
    39. Remove the bolt that secures the fuel line bracket to the left side of the transmission.
    40.  
    41. Remove the torque converter bolts.
    42.  
    43. Disconnect the transmission oil cooler lines.
    44.  
    45. Plug the transmission oil cooler line fittings.
    46.  
    47. Remove the fuel feed/return and evaporative emission (EVAP) return pipe bracket nut.
    48.  
    49. Remove the lower right transmission bolt and stud.
    50.  
    51. Remove the remaining transmission studs and bolt.
    52.  
    53. Install the torque converter holding tool J-21366 onto the transmission in order to retain the torque converter.
    54.  
    55. Pull the transmission straight back.
    56.  
    57. Remove the transmission from the vehicle while simultaneously removing the fluid level indicator tube.
    58.  
    59. Flush the transmission oil cooler and cooling lines when you remove the transmission.

      Click image to see an enlarged view

      Fig. 2002-06 4L60-E/4L65-E transmission removal

    60.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Raise the transmission into place while simultaneously installing the fluid indicator tube.
    4.  
    5. Remove the holding tool.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand.
    8.  
    9. Install the transmission studs and bolt and tighten to 37 ft. lbs. (50 Nm).
    10.  
    11. Install the lower right transmission stud and bolt and tighten to 37 ft. lbs. (50 Nm).
    12.  
    13. Install the fuel feed/return and EVAP return pipe bracket nut.
    14.  
    15. Remove the plugs from the transmission oil cooler line fittings.
    16.  
    17. Connect the transmission oil cooler lines.
    18.  
    19. If reusing the torque converter bolts, clean the bolt threads and apply Loctite 242, or equivalent to the threads prior to installation.
    20.  
    21. Install the torque converter bolts and tighten to 46 ft. lbs. (63 Nm).
    22.  
    23. Install the bolt that secures the fuel line bracket to the left side of the transmission.
    24.  
    25. Connect the VSS and the main electrical connectors.
    26.  
    27. Connect the PNP switch electrical connectors.
    28.  
    29. Install the harness clip to the fuel line bracket.
    30.  
    31. Install the exhaust hanger bracket and bolts and tighten to 13 ft. lbs. (17 Nm).
    32.  
    33. Install the cable to the bracket.
    34.  
    35. Install the range selector cable end to the transmission range selector lever ball stud.
    36.  
    37. Ensure the transmission manual shaft is positioned in mechanical park.
    38.  
    39. Install the retainer that secures the cable to the bracket.
    40.  
    41. Install the transmission mount and bolts and tighten to 18 ft. lbs. (25 Nm).
    42.  
    43. Install the transfer case, if equipped,
    44.  
    45. Install the starter.
    46.  
    47. Install the exhaust pipe
    48.  
    49. Raise the transmission slightly and install the transmission support.
    50.  
    51. Install the transmission support bolts/nuts and tighten to 70 ft. lbs. (95 Nm).
    52.  
    53. Install the transmission mount nuts and tighten to 37 ft. lbs. (50 Nm).
    54.  
    55. Remove the support from the transmission.
    56.  
    57. Install the driveshaft.
    58.  
    59. Connect the negative battery cable.
    60.  
    61. Fill the transmission to the proper level with DEXRON® VI transmission fluid.
    62.  

    4L60E, 4L65E & 4L70E



    1. Remove or disconnect the following:
      NOTE
      Plug the oil level indicator tube opening in the transmission.



      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       



      Shift cable end from the transmission shift lever ball stud
       
      Front propeller shaft, if 4WD
       
      Rear propeller shaft.
       

    2.  
    3. Plug the transmission oil cooler line connectors in the transmission case.
    4.  
    5. Remove or disconnect the following:

      Starter motor
       

    6.  
    7. Support the transmission with a transmission jack.
    8.  
    9. Remove or disconnect the following:

      Click image to see an enlarged view

      Fig. 4L60E removal; 4L65E and 4L70E similar



      Torque converter access plug
       
      Flywheel-to-torque converter bolts
       
      Transmission rear mount-to-transmission bolts and nut
       
      Heat shield-to-transmission bolts
       
      Transmission vent hose from the transmission
       
      Fuel lines from the transmission
       
      Wiring harness from the transmission
       
      Transmission-to-engine stud and bolt
       
      Studs and bolt securing the transmission to the engine.
       

    10.  
    11. Install tool J21366 onto the transmission bell housing to retain the torque converter. Pull the transmission straight back.
    12.  
    13. The transmission from the vehicle
    14.  
    15. Flush the transmission oil cooler and cooling lines.
    16.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      Studs and bolt securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Flywheel to torque converter bolts. Tighten to 46 ft. lbs. (63 Nm) and use Loctite 242 on the threads
       
      Torque converter access plug
       
      Transmission vent hose to the transmission
       
      Fuel lines to the transmission
       
      Wiring harness to the transmission.
       
      Heat shield-to-transmission bolts and tighten to 13 ft. lbs. (17 Nm)
       
      Transmission rear mount-to-transmission bolt and nut and tighten to 18 ft. lbs. (25 Nm)
       

    10.  
    11. Remove the transmission jack from the transmission.
    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Install or connect the following:

      Transmission oil cooler lines
       
      Front propeller shaft, if equipped
       
      Rear propeller shaft
       
      Shift cable end to the transmission shift lever ball stud
       

    16.  
    17. Unplug the oil level indicator tube opening in the transmission.
    18.  
    19. Install the transmission oil level indicator tube and seal to the transmission.
    20.  
    21. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    22.  
    23. Lower the vehicle.
    24.  

    4l80-E/4l85-E Transmissions



    1. Remove or disconnect the following:

      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       

    2.  
    3. Plug the oil level indicator tube opening in the transmission.

      Shift cable from the transmission shift lever ball stud
       
      Front propeller shaft, if 4WD
       
      Rear propeller shaft.
       
      Transmission oil cooler lines, then plug thee openings in the transmission case
       
      Starter motor
       

    4.  
    5. Support the transmission with a transmission jack.

      Heat shield
       
      Transmission vent hose
       
      Fuel lines from the transmission
       
      Wiring harness from the transmission
       
      Transmission brace-to-engine bracket and transmission nut and bolt
       
      Torque converter cover
       
      Flywheel to torque converter bolts
       
      Transmission rear mount
       
      Stud and bolt on the right side securing the transmission to the engine
       
      Remaining six studs and the bolt securing the transmission to the engine
       

    6.  
    7. Install Tool J21366 onto the transmission bell housing to retain the torque converter.

      Click image to see an enlarged view

      Fig. 4L80E removal-Silverado shown

    8.  
    9. Pull the transmission straight back. Remove the transmission from the vehicle.
    10.  
    11. Flush the transmission oil cooler and cooling lines when you remove the transmission.
    12.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      Six studs and bolt securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Stud and bolt on the right side securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Flywheel-to-torque converter bolts and tighten to 44 ft. lbs. (60 Nm).
       
      Torque converter cover-to-engine bolts and tighten to 37 ft. lbs. (50 Nm)
       
      Torque converter cover-to-transmission stud and bolt and tighten to 24 ft. lbs. (33 Nm).
       
      Transmission vent hose
       
      Fuel lines
       
      Wiring harness
       
      Heat shield. Tighten the bolts to 13 ft. lbs. (17 Nm).
       
      Transmission rear mount-to-transmission nuts and bolt. Tighten to 18 ft. lbs. (25 Nm).
       
      Transmission brace. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
       

    10.  
    11. Remove the transmission jack from the transmission.

      Starter motor
       

    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Connect the transmission oil cooler lines to the transmission.
    16.  
    17. Install or connect the following:

      Rear propeller shaft
       
      Front propeller shaft, if 4WD
       
      Shift cable end to the transmission shift lever ball stud
       

    18.  
    19. Unplug the oil level indicator tube opening in the transmission.
    20.  
    21. Install the transmission oil level indicator tube and seal to the transmission.
    22.  
    23. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    24.  
    25. Lower the vehicle.
    26.  

    1. Drain the transmission fluid.
    2.  
    3. Remove the driveshaft.
    4.  
    5. Support the transmission with a suitable jack.
    6.  
    7. Remove the transmission mount nuts.
    8.  
    9. Remove the transmission support bolts/nuts.
    10.  
    11. Remove the transmission support.
    12.  
    13. Raise the transmission slightly and remove the transmission support from the vehicle.
    14.  
    15. Remove the exhaust manifold pipe.
    16.  
    17. Remove the transfer case, if equipped.
    18.  
    19. Remove the transmission mount bolts and mount.
    20.  
    21. Ensure the transmission manual shaft is positioned in mechanical park.
    22.  
    23. Remove the retainer that secures the cable to the bracket.
    24.  
    25. Remove the range selector cable end from the transmission range selector lever ball stud.
    26.  
    27. Depress the tangs and remove the cable from the bracket.
    28.  
    29. Disconnect the input speed sensor, output speed sensor, park/neutral switch and transmission electrical connectors.
    30.  
    31. Disconnect the oxygen sensor (HO 2 S) electrical connector.
    32.  
    33. Disconnect the wire harness clip from the bracket on the left side of the transmission.
    34.  
    35. Cut the tie strap to separate the vent hose from the wiring harness.
    36.  
    37. Remove the flywheel inspection cover.
    38.  
    39. Mark the torque converter to flywheel orientation.
    40.  
    41. Remove the torque converter bolts.
    42.  
    43. If equipped with a 6.0L or 8.1L engine, remove the exhaust hanger mounting bracket bolts and bracket.
    44.  
    45. Disconnect and plug the transmission oil cooler lines.
    46.  
    47. Remove the stud on the left side of the transmission.
    48.  
    49. Remove the remaining transmission studs.
    50.  
    51. Install torque converter holding tool J-21366 onto the transmission bell housing to retain the torque converter.
    52.  
    53. Pull the transmission straight back.
    54.  
    55. Remove the transmission from the vehicle.
    56.  
    57. Flush the transmission oil cooler and lines at this time.

      Click image to see an enlarged view

      Fig. 2002-06 4L80-E/4L85-E transmission removal

    58.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Install the transmission to the vehicle.
    4.  
    5. Raise the transmission into place and remove the holding tool.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must rotate freely by hand.
    8.  
    9. Install the transmission studs and tighten to 37 ft. lbs. (50 Nm).
    10.  
    11. Install the stud on the left side of the transmission and tighten to 37 ft. lbs. (50 Nm).
    12.  
    13. Remove the plugs from the transmission oil cooler line fittings.
    14.  
    15. Connect the transmission oil cooler lines.
    16.  
    17. If equipped with a 6.0L or 8.1L engine, install the exhaust hanger mounting bracket and bolts.
    18.  
    19. Align the torque converter to the flywheel.
    20.  
    21. If reusing the torque converter bolts with a 6.0L or 8.1L engine, clean the bolt threads and apply Loctite 242, or equivalent to the threads prior to installation.
    22.  
    23. Install the torque converter bolts and tighten to 44 ft. lbs. (60 Nm).
    24.  
    25. Install the flywheel inspection cover and tighten to 24 ft. lbs. (33 Nm).
    26.  
    27. Connect the wire harness clip to the bracket on the left side of the transmission.
    28.  
    29. Connect the oxygen sensor (HO 2 S) electrical connector.
    30.  
    31. Connect the input speed sensor, output speed sensor, park/neutral switch and transmission electrical connectors.
    32.  
    33. Depress the tangs and install the cable to the bracket.
    34.  
    35. Install the range selector cable end to the transmission range selector lever ball stud.
    36.  
    37. Ensure the transmission manual shaft is positioned in mechanical park.
    38.  
    39. Install the retainer that secures the cable to the bracket.
    40.  
    41. Install the transmission mount and bolts and tighten to 18 ft. lbs. (25 Nm).
    42.  
    43. Install the transfer case, if equipped.
    44.  
    45. Install the exhaust manifold pipe.
    46.  
    47. Install the transmission support.
    48.  
    49. Install the transmission support bolts/nuts and tighten to 75 ft. lbs. (95 Nm).
    50.  
    51. Install the transmission mount nuts and tighten to 37 ft. lbs. (50 Nm).
    52.  
    53. Remove the support from the transmission.
    54.  
    55. Install the driveshaft.
    56.  
    57. Connect the negative battery cable.
    58.  
    59. Fill the transmission to the proper level with Dexron® VI transmission fluid.
    60.  

    4L80E & 4L85E



    1. Remove or disconnect the following:

      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       

    2.  
    3. Plug the oil level indicator tube opening in the transmission.

      Shift cable from the transmission shift lever ball stud
       
      Front propeller shaft, if 4WD
       
      Rear propeller shaft.
       
      Transmission oil cooler lines, then plug thee openings in the transmission case
       
      Starter motor
       

    4.  
    5. Support the transmission with a transmission jack.

      Heat shield
       
      Transmission vent hose
       
      Fuel lines from the transmission
       
      Wiring harness from the transmission
       
      Transmission brace-to-engine bracket and transmission nut and bolt
       
      Torque converter cover
       
      Flywheel to torque converter bolts
       
      Transmission rear mount
       
      Stud and bolt on the right side securing the transmission to the engine
       
      Remaining six studs and the bolt securing the transmission to the engine
       

    6.  
    7. Install Tool J21366 onto the transmission bell housing to retain the torque converter.

      Click image to see an enlarged view

      Fig. 4L80E removal; 4L85E similar

    8.  
    9. Pull the transmission straight back. Remove the transmission from the vehicle.
    10.  
    11. Flush the transmission oil cooler and cooling lines when you remove the transmission.
    12.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      Six studs and bolt securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Stud and bolt on the right side securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Flywheel-to-torque converter bolts and tighten to 44 ft. lbs. (60 Nm).
       
      Torque converter cover-to-engine bolts and tighten to 37 ft. lbs. (50 Nm)
       
      Torque converter cover-to-transmission stud and bolt and tighten to 24 ft. lbs. (33 Nm).
       
      Transmission vent hose
       
      Fuel lines
       
      Wiring harness
       
      Heat shield. Tighten the bolts to 13 ft. lbs. (17 Nm).
       
      Transmission rear mount-to-transmission nuts and bolt. Tighten to 18 ft. lbs. (25 Nm).
       
      Transmission brace. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
       

    10.  
    11. Remove the transmission jack from the transmission.

      Starter motor
       

    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Connect the transmission oil cooler lines to the transmission.
    16.  
    17. Install or connect the following:

      Rear propeller shaft
       
      Front propeller shaft, if 4WD
       
      Shift cable end to the transmission shift lever ball stud
       

    18.  
    19. Unplug the oil level indicator tube opening in the transmission.
    20.  
    21. Install the transmission oil level indicator tube and seal to the transmission.
    22.  
    23. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    24.  
    25. Lower the vehicle.
    26.  

    4l80e Transmissions



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       

    4.  
    5. Plug the oil level indicator tube opening in the transmission.
    6.  
    7. Remove or disconnect the following:

      Shift cable from the transmission shift lever ball stud
       
      Propeller shaft(s), as necessary
       
      Transmission oil cooler lines from the transmission
       

    8.  
    9. Plug the transmission oil cooler line connectors in the transmission case.

      Starter motor
       

    10.  
    11. Support the transmission with a transmission jack.

      Two bolts securing the heat shield to the transmission
       
      Transmission vent hose, fuel lines, and the wiring harness from the transmission
       
      Nut and bolt securing the transmission brace to the engine bracket and transmission
       
      Two bolts securing the torque converter cover to the engine
       
      Four bolts securing the torque converter cover to the transmission
       
      Six flywheel-to-torque converter bolts
       
      Two bolts and nut securing the transmission rear mount to the transmission
       
      Stud and the bolt on the right side securing the transmission to the engine
       
      Remaining six studs and the one bolt securing the transmission to the engine
       

    12.  
    13. Install Tool J21366 onto the transmission bell housing to retain the torque converter

      Click image to see an enlarged view

      Fig. 2000-01 4L80E removal

    14.  
    15. Pull the transmission straight back. Remove the transmission from the vehicle.
    16.  
    17. Flush the transmission oil cooler and cooling lines when you remove the transmission.
    18.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      Six studs and one bolt securing the transmission to the engine. Tighten the studs and the bolt to 37 ft. lbs. (50 Nm).
       
      Stud and bolt on the right side securing the transmission to the engine. Tighten the stud and the bolt to 37 ft. lbs. (50 Nm).
       
      Six flywheel-to-torque converter bolts. Tighten the bolts to44 ft. lbs. (60 Nm).
       
      Two bolts securing the torque converter cover to the engine. Tighten the bolt to 37 ft. lbs. (50 Nm).
       
      Four bolts securing the torque converter cover to the transmission. Tighten the stud and the bolt to 24 ft. lbs. (33 Nm).
       
      Transmission vent hose, fuel lines, and the wiring harness to the transmission
       
      Two bolts securing the heat shield to the transmission. Tighten the bolt to 13 ft. lbs. (17 Nm).
       
      Two bolts and nut securing the transmission rear mount to the transmission. Tighten the bolts and nut to 18 ft. lbs. (25 Nm).
       
      Flywheel-to-torque converter bolts
       
      Nut and bolt securing the transmission brace to the engine bracket and transmission. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
       

    10.  
    11. Remove the transmission jack from the transmission.

      Starter motor
       

    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Connect the transmission oil cooler lines to the transmission.
    16.  
    17. Install or connect the following:

      Transfer case
       
      Rear driveshaft
       
      Shift cable end to the transmission shift lever ball stud
       

    18.  
    19. Unplug the oil level indicator tube opening in the transmission.
    20.  
    21. Install the transmission oil level indicator tube and seal to the transmission.
    22.  
    23. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    24.  
    25. Lower the vehicle.
    26.  

    6L80E & 6L90E



    1. Remove or disconnect the following:

      Transmission fluid
       
      Transmission oil level indicator tube and seal from the transmission
       

    2.  
    3. Plug the oil level indicator tube opening in the transmission.

      Shift cable from the transmission shift lever ball stud
       
      Front propeller shaft, if 4WD
       
      Rear propeller shaft.
       
      Transmission oil cooler lines, then plug thee openings in the transmission case
       
      Starter motor
       
      Transfer case, if 4WD
       

    4.  
    5. Support the transmission with a transmission jack.

      Heat shield
       
      Transmission vent hose
       
      Fuel lines from the transmission
       
      Wiring harness from the transmission
       
      Transmission brace-to-engine bracket and transmission nut and bolt
       
      Torque converter cover
       
      Flywheel to torque converter bolts
       
      Transmission rear mount
       
      8 bolts securing the transmission to the engine
       

    6.  
    7. Install Tool J21366 onto the transmission bell housing to retain the torque converter.

      Click image to see an enlarged view

      Fig. 6L series mounting bolt locations

    8.  
    9. Pull the transmission straight back. Remove the transmission from the vehicle.
    10.  
    11. Flush the transmission oil cooler and cooling lines when you remove the transmission.
    12.  

    To install:

    1. Install Tool J21366 onto the transmission bell housing to retain the torque converter.
    2.  
    3. Support the transmission with a transmission jack.
    4.  
    5. Raise the transmission into place and remove the tool from the transmission.
    6.  
    7. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter. The torque converter must be flush onto the flywheel and rotate freely by hand.
    8.  
    9. Install or connect the following:

      8 bolts securing the transmission to the engine. Tighten to 37 ft. lbs. (50 Nm).
       
      Flywheel-to-torque converter bolts and tighten to 46 ft. lbs. (63 Nm). Use Loctite 242 on the threads
       
      Transmission vent hose
       
      Fuel lines
       
      Wiring harness
       
      Heat shield.
       
      Transmission rear mount-to-transmission nuts and bolt.
       
      Transmission brace.
       

    10.  
    11. Remove the transmission jack from the transmission.

      Starter motor
       
      Transfer case, if 4WD
       

    12.  
    13. Unplug the transmission oil cooler line connectors in the transmission case.
    14.  
    15. Connect the transmission oil cooler lines to the transmission.
    16.  
    17. Install or connect the following:

      Rear propeller shaft
       
      Front propeller shaft, if 4WD
       
      Shift cable end to the transmission shift lever ball stud
       

    18.  
    19. Unplug the oil level indicator tube opening in the transmission.
    20.  
    21. Install the transmission oil level indicator tube and seal to the transmission.
    22.  
    23. Tighten the oil pan bolts and fill the transmission with transmission fluid.
    24.  
    25. Lower the vehicle.
    26.  

    Allison Transmissions



    1. Drain the transmission.
    2.  
    3. Disconnect both negative battery cables.
    4.  
    5. Remove the transmission fluid level indicator.
    6.  
    7. Remove the right front wheel and tire.
    8.  
    9. Remove the right front wheel house inner panel retainers.
    10.  
    11. Disconnect any harness retainers attached to the inner panel.
    12.  
    13. Remove the inner panel.
    14.  
    15. Remove the starter.
    16.  
    17. Remove the engine protection shield bolts and shield.
    18.  
    19. Rotate the engine clockwise, using the crankshaft bolt in order to access the torque converter bolts thru the starter opening. Have an assistant rotate the engine while aligning the bolts.
    20.  
    21. Remove the torque converter bolts.
    22.  
    23. Completely raise the vehicle.
    24.  
    25. Disconnect the shift cable from the selector lever ball stud and remove the cable from the bracket.
    26.  
    27. Remove the shift cable bracket bolts and bracket from the transmission.
    28.  
    29. Reposition the bracket with the cable attached off to the side.
    30.  
    31. Remove the fuel line retainer bolts on the left side of the transmission.
    32.  
    33. Remove the fuel line bracket nut from the converter housing stud.
    34.  
    35. Disconnect the turbine speed sensor and input speed sensor electrical connectors.
    36.  
    37. Disconnect the output speed sensor electrical connector.
    38.  
    39. If the vehicle is equipped with 4 wheel drive (4WD), the output speed sensor is located on the transfer case and will be disconnected later.
    40.  
    41. Disconnect the transmission main electrical connector.
    42.  
    43. Disconnect the park/neutral position (PNP) switch electrical connector.
    44.  
    45. Remove the exhaust hanger bolts and reposition the hanger.
    46.  
    47. If the vehicle is a 2 wheel drive (2WD), remove the propeller shaft.
    48.  
    49. Support the transmission with a transmission jack.
    50.  
    51. If the vehicle is a 2WD, remove the transmission mount nuts.
    52.  
    53. If the vehicle is a 2WD, remove the transmission support bolts and nuts.
    54.  
    55. Remove the transmission mount bolts and mount.
    56.  
    57. If the vehicle is equipped with 4WD, remove the transfer case.
    58.  
    59. Reposition any wiring harness branches out of the way.
    60.  
    61. Secure a safety chain around the transmission. Use care not to overlap any wiring, fuel lines, or other related components.
    62.  
    63. Disconnect and plug the transmission oil cooler lines from the transmission.
    64.  
    65. If the vehicle is equipped with a power take off (PTO) unit , disconnect and/or remove any necessary components to facilitate transmission removal.
    66.  
    67. Remove the transmission fill tube nuts from the converter housing studs.
    68.  
    69. Remove the wire harness/vent tube bracket nut from the converter housing stud and reposition the bracket.
    70.  
    71. Remove the remaining converter housing bolts and studs.
    72.  
    73. Separate the transmission from the engine.
    74.  
    75. Install torque converter holding tool J-21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
    76.  
    77. Carefully lower the transmission from the vehicle while simultaneously removing the fill tube.
    78.  
    79. Remove the holding tool.
    80.  

    To install:

    1. Install torque converter holding tool J-21366 to the converter housing in order to keep the torque converter from sliding off of the turbine shaft.
    2.  
    3. Raise the transmission into place while simultaneously installing the transmission fill tube.
    4.  
    5. Remove the holding tool.
    6.  
    7. Align the transmission with the engine using the alignment dowels located at the rear of the engine.
      NOTE
      Ensure that the torque converter can be rotated before tightening the bolts and studs.

    8.  
    9. Install the converter housing bolts and studs and tighten to 37 ft. lbs. (50 Nm).
    10.  
    11. Install the wire harness/vent tube bracket and nut to the converter housing stud.
    12.  
    13. Install the transmission fill tube and nuts to the converter housing studs.
    14.  
    15. If the vehicle is equipped with a PTO unit, connect and/or install the components at this time.
    16.  
    17. Remove the safety chain from around the transmission.
    18.  
    19. Install the transfer case, if the vehicle is equipped with 4WD.
    20.  
    21. If the vehicle is a 2WD, install the transmission mount and tighten to 37 ft. lbs. (50 Nm).
    22.  
    23. Install the transmission support and tighten to 70 ft. lbs. (95 Nm).
    24.  
    25. If the vehicle is a 2WD, install the transmission mount nuts and tighten to 30 ft. lbs. (40 Nm).
    26.  
    27. Remove the transmission jack.
    28.  
    29. If the vehicle is a 2WD, install the propeller shaft.
    30.  
    31. Position the exhaust hanger and install the bolts.
    32.  
    33. Position the wiring harness branches.
    34.  
    35. Connect the PNP switch electrical connectors.
    36.  
    37. Connect the transmission main electrical connector
    38.  
    39. Connect the output speed sensor electrical connector. If the vehicle is equipped with 4WD, the output speed sensor is located on the transfer case and has been connected during the transfer case installation.
    40.  
    41. Connect the turbine speed sensor and the input speed sensor electrical connectors.
    42.  
    43. Install the fuel line bracket and nut to the transmission converter housing stud.
    44.  
    45. Install the fuel line retainer and bolts to the left side of the transmission.
    46.  
    47. Install the shift cable bracket and bolts to the transmission.
    48.  
    49. Install the shift cable to the bracket and the selector lever ball stud.
    50.  
    51. Remove the access hole cover on the converter housing in order to rotate the converter and align the first torque converter bolt. If reusing the torque converter bolts, clean the bolt threads and apply Loctite® or equivalent to the threads prior to installation.
    52.  
    53. Install the torque converter bolts and tighten to 44 ft. lbs. (760 Nm).
    54.  
    55. Install the converter housing access hole cover.
    56.  
    57. Install the engine protection shield and bolts.
    58.  
    59. Position and install the starter.
    60.  
    61. Install the inner panel.
    62.  
    63. Connect any harness retainers to the inner panel.
    64.  
    65. Install the right front wheel house inner panel retainers.
    66.  
    67. Install the right front wheel and tire.
    68.  
    69. Remove the plugs from the transmission oil cooler line fittings in the transmission case, if necessary.
    70.  
    71. Flush the transmission oil cooler and lines, if necessary.
    72.  
    73. Connect the transmission oil cooler lines to the transmission.
    74.  
    75. Lower the vehicle.
    76.  
    77. Connect both negative battery cables.
    78.  
    79. Fill the transmission with new transmission fluid.
    80.  
    81. Install the transmission fluid level indicator.
    82.  
    83. If a replacement transmission was installed, perform the Fast Learn procedure using a scan tool.
    84.  

     
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