4L80-E Automatic Transmission

REMOVAL PROCEDURE

- Tools Required
- J21366 Converter Holding Strap

1. Disconnect the battery negative cable assembly from the battery negative terminal.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

2. Raise the vehicle. Support the vehicle with safety stands. Refer to Vehicle Lift Points.
3. Disconnect the range selector cable from the transmission bracket. Refer to Shift Cable Replacement.
4. Disconnect the range selector cable from the transmission range selector lever. Refer to Shift Cable Replacement
5. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement-One-Piece, Propeller Shaft Replacement-Two-Piece, or Propeller Shaft Replacement-Three-Piece in Propeller Shaft.
6. Support the transmission with a transmission jack.
7. For the 4WD vehicles, remove the transfer case. Refer to one of the following procedures in Transfer Case:
- Transfer Case Replacement (Selectable Four Wheel Drive)
- Transfer Case Replacement (Auto Four Wheel Drive)
- Transfer Case Replacement (Manual Four Wheel Drive)

8. Gasoline Engine: Remove the following components:
8.1. Two bolts
8.2. Two washers
8.3. One nut
8.4. The transmission to engine brace

9. Diesel Engine: Remove the following components:
9.1. Two bolts
9.2. Two washers
9.3. The transmission to engine brace

10. Remove the nut and washer securing the transmission mount to the crossmember.
11. Remove the two bolts and washers securing the mount to the transmission.
12. Remove the bolts and nuts securing the crossmember to the frame.
13. Remove the exhaust pipe from the exhaust manifolds. Remove the muffler assembly from the exhaust pipe, if required.

14. Five liter and 4.3L Gasoline Engine-Remove the six bolts securing the converter cover to the transmission.
15. Mark the flywheel and the torque converter alignment.

16. Diesel Engine and 7.4L & 5.7L Engines-Remove the four bolts securing the converter cover to the transmission.
17. Mark the flywheel and the torque converter alignment.

18. Remove the bolts that attach the torque converter to the engine flywheel.

19. Remove the transmission vent hose.
20. Disconnect the wiring harness connectors from the vehicle speed sensors and from the park neutral position switch.
21. Remove all vehicle electrical harness wires, harness clips, tubes, and brackets that may interfere with the removal of the transmission.
22. Remove the fluid fill tube and the fill tube seal from the transmission. Refer to Filler Tube and Seal Replacement
23. Plug the fluid fill tube opening in the transmission.
24. Disconnect the transmission oil cooler pipes from the transmission. Refer to Oil Cooler Line Replacement.
25. Plug the transmission oil cooler pipe connectors in the transmission case.
26. Install the J21366 in order to keep the torque converter from sliding off of the transmission turbine shaft.
27. Support the engine with a suitable jack stand before removing the transmission from the engine.

28. Remove the six studs securing the transmission to the engine.
29. Pull the transmission straight back from the engine.
30. Lower the transmission using the transmission jack.
31. Flush the transmission oil cooler and the pipes whenever you remove the transmission for overhaul, or replacement of the torque converter, the pump, or the transmission case. Refer to AT Oil Cooler Flushing.
32. Clean the transmission case using a solvent dampened cloth. Do not allow solvent to enter the transmission.
33. Air dry the transmission.
34. Clean all hardware and the flywheel cover using solvent. Air dry all the parts.
35. Inspect all the components for wear and damage.
36. Inspect all the seals and the fittings for signs of wear.
37. Inspect the torque converter for stripped or broken weld nuts.
38. Inspect the transmission case for cracks.
39. Clean the transmission case using a solvent dampened cloth.
40. Do not allow solvent to enter the transmission. Air dry.
41. Inspect all of the components for wear and damage.
42. Inspect all the seals and the fittings for signs of wear.
43. Inspect the torque converter for stripped or broken weld nuts.
44. Inspect the transmission case for cracks.

INSTALLATION PROCEDURE

- Tools Required
- J21366 Converter Holding Strap

IMPORTANT: The torque converter and the flywheel must be aligned and must rotate freely.

Install the brackets, the clips, and the harnesses to the original locations.

Do not install the oil level indicator tube.

1. Install the J21366 in order to keep the torque converter from sliding off of the transmission turbine shaft.

2. Install the six studs that are securing the transmission to the engine in the following way:
2.1. Raise the transmission into place and remove the J21366.
2.2. Support the transmission with a transmission jack.
2.3. Slide the transmission straight onto the locating pins while lining up the marks on the flywheel and the torque converter.

3. Tighten the six studs.
- Tighten the studs to 47 Nm (34 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.

4. Install the transmission vent hose.
5. Connect the wiring harness connectors to the vehicle speed sensors and to the park neutral position switch.
6. Install all of the vehicle electrical harness wires, harness clips, tubes, and brackets removed before transmission removal.
7. Remove the two plugs from the transmission case cooler pipe connectors.
8. Install the transmission cooler pipes. Refer to Oil Cooler Line Replacement.
9. Install the transmission fluid fill tube and the fill tube seal. Refer to Filler Tube and Seal Replacement.

10. Install the three bolts securing the torque converter to the engine flywheel.
10.1. Tighten the bolts finger tight in order to insure proper converter seating.
10.2. Tighten the bolts to 67 Nm (49 ft. lbs.).

11. For the 6.5 liter diesel engine and the 7.4L/5.7L gasoline engines, Install the bolts securing the converter cover to the transmission.
- Tighten the converter cover bolts to 33 Nm (24 ft. lbs.).

12. For the 5.0L gasoline engine, install the bolts securing the converter cover to the transmission.
- Tighten the converter cover bolts to 33 Nm (24 ft. lbs.).

13. Install the exhaust pipe from the exhaust manifolds and the muffler assembly from the exhaust pipe if required. Refer to Exhaust Manifold Replacement (Left Side) or Exhaust Manifold Replacement (Right Side) in Powertrain Management.
14. Install the bolts securing the crossmember to the frame.
- Tighten the bolts to 77 Nm (56 ft. lbs.).

15. Install the two bolts and washers securing the mount to the transmission.
- Tighten the bolts to 47 Nm (35 ft. lbs.).

16. Install the nut and the washer securing the transmission mount to the crossmember.
- Tighten the bolts to 52 Nm (38 ft. lbs.).

17. For a gasoline engine, install the two bolts, the two washers, and a nut securing the brace to the engine and the transmission.
- Tighten the bolts to 55 Nm (41 ft. lbs.).

18. For a diesel engine, install the two bolts, the two washers, and a nut securing the brace to the engine and the transmission.
- Tighten the bolts to 70 Nm (51 ft. lbs.).

19. For a 4WD vehicle, install the transfer case to the transmission. Refer to one of the following procedures in Transfer Case:
- Transfer Case Replacement (Selectable Four Wheel Drive)
- Transfer Case Replacement (Auto Four Wheel Drive)
- Transfer Case Replacement (Manual Four Wheel Drive)

20. Remove the transmission jack and the engine support stands.
21. Install the rear propeller shaft. Refer to Propeller Shaft Replacement-One-Piece, Propeller Shaft Replacement-Two-Piece, or Propeller Shaft Replacement-Three-Piece in Propeller Shaft.
22. Install the transmission range select cable to the transmission range select lever and the bracket. Refer to Shift Cable Replacement.
23. Remove the safety stands.
24. Lower the vehicle.
25. Fill with new transmission fluid. Refer to Fluid Capacity Specifications (On-Vehicle) and to Transmission Fluid Checking Procedure.
26. Connect the battery negative cable assembly to the battery negative terminal.
- Tighten the terminal bolt to 15 Nm (11 ft. lbs.).