Manual Control Lever Shaft and Seal
Manual Control Lever Shaft and SealSpecial Tool(s):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist.
2. If equipped, remove the heat shield.
3. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.
4. CAUTION: Do not pull on the wire harness to disconnect the connector or damage to the connector will occur.
Disconnect the main transmission electrical harness by twisting the outer shell and pulling back on the connector.
5. Remove the transmission fluid pan and allow the fluid to drain.
6. Remove the fluid pan gasket.
7. Remove and discard the transmission fluid filter.
8. Clean and inspect the transmission fluid pan and magnet.
9. Press the release tab and pull down on the bulkhead connector retainer.
10. With the release tab down, pull the outer shell of the bulkhead electrical connector.
11. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
Pull the outer shell of the bulkhead electrical connector out of the transmission.
12. NOTE: During removal of the mechatronic assembly, the thermal bypass valve, pump adapter seal and one or more center support seals may become dislodged. Save these components for reuse during assembly.
Remove the 10 bolts from the mechatronic assembly and remove the mechatronic assembly.
13. Remove the park rod actuating plate.
14. Remove the manual control lever.
1 Remove the roll pin.
2 Slide the manual control lever shaft out of the case.
3 Hold the spacer to keep it from falling out of the case.
4 Remove the manual valve inner lever and the park rod as an assembly.
15. Remove and discard the manual control lever seal.
Installation
1. Position a new manual control lever seal in place.
2. Using the special tool, install a new manual control lever shaft seal.
3. Install the manual lever in the case.
1 Slide the manual lever in the case.
2 Position the spacer in place while sliding the manual lever into the spacer.
3 Position the manual valve inner lever while sliding the manual lever and lining up the roll pin hole.
4 Install the roll pin.
4. Position the park rod in place. Push down on the park pawl and position the park rod in place.
5. While holding the park rod down, install the park rod actuating plate.
^ Tighten to 10 Nm (89 lb-in).
6. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note that one or more of the center support seals may have remained in the mechatronic assembly during removal and should be installed into the transmission case at this time.
Verify the 4 rubber feed tubes for the center support are in place.
7. Verify the thermal bypass valve is in the case.
8. Verify the rubber adapter is in place.
9. CAUTION: Do not touch the electrical connector pins or the exposed solenoid tabs on the transmission control module (TCM). Electrostatic discharge may occur and may cause damage to the mechatronic unit.
Position the mechatronic assembly in place and loosely install the 10 bolts.
1 Align the manual valve and control lever linkage.
10. Tighten the mechatronic bolts in the sequence shown.
^ Tighten to 8 Nm (71 lb-in).
11. Install new O-rings on the outer shell of the bulkhead electrical connector.
12. CAUTION: Do not touch the electrical connector pins. Electrostatic charge may occur and will cause damage to the mechatronic unit.
With the release tab down, push the outer shell of the bulkhead electrical connector into the transmission.
13. Press up on the tab and lock the outer shell of the bulkhead electrical connector in place.
14. Install a new transmission fluid filter.
15. Install the fluid pan gasket.
16. Install the fluid pan and bolts.
^ Tighten to 12 Nm (9 lb-ft).
17. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.
18. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the bracket. Also, make sure that the selector lever cable end is correctly installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is correctly installed.
Connect the selector lever cable onto the ball stud and move the locking tab down.
^ Listen for the audible click.
^ Pull back on the selector lever cable to make sure that it is correctly installed.
19. If equipped, install the heat shield.
20. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields.
Remove the fluid fill plug located on the RH rear side of the case near the transmission electrical connector.
21. CAUTION: The use of any other transmission fluid than specified can result in the transmission failing to operate correctly or transmission failure.
CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields.
Fill the transmission.
^ Add 4.7 liters (5 quarts) of clean automatic transmission fluid to the transmission through the fluid fill hole. Stop when the fluid runs out of the bottom of the hole.
22. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
23. With the special tool connected, the engine idling (550-750 rpm) in PARK and the transmission temperature at 30°C-50°C (86°F-122°F), check and adjust the transmission fluid level.
24. CAUTION: The fluid fill plug located on the side of the transmission is near the exhaust system. The exhaust will be extremely hot during this procedure. Use care when working near the exhaust and the heat shields.
Fill with clean automatic transmission fluid until the fluid runs out of the bottom of the hole.
25. Install the fluid fill plug.
^ Tighten to 35 Nm (26 lb-ft).
