Service Procedure

Important
The service procedure contained in this program is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.

Case Inspection and Pump Repair Procedure

External Inspection of the Transmission Case Casting for Affected Vehicles

The transmission case has some external differences between the 1st design and the 2nd design. The differences between the 1st design and 2nd design provide for an inspection procedure to determine which transmissions will require a pump repair procedure to be performed.

Inspection Procedure

1. Prep the vehicle.

2. Raise the vehicle.

3. Inspect the transmission case to determine first design or second design case. The 1st design cases do not need additional service. The 2nd design cases require the Pump Repair Procedure to be performed.

4. Look at the transmission from under the vehicle on the passenger's side in order to determine first design or second design transmission case. The 1st design cases do not need additional service. The 2nd design cases require the Pump Repair Procedure to be performed.

5. Inspect the area by the cooler line quick connect fitting near the bar code label on the right side of the transmission case.





^ If there are two bosses, as in the left picture, the vehicle CAN BE RELEASED FOR SALE.

^ If there is only one boss, as in the right picture, then the vehicle MUST BE HELD FOR REPAIR.

Important
Do not perform the Pump Repair Procedure on 1st design cases. ALL transmission with the 2nd design case require the Pump Repair Procedure to be performed.

6. Verify vehicle mileage.

7. For vehicles with less than twenty miles (32 km): Repair the pump utilizing the plug parts kit and Pump Repair Procedure Remove the transmission and transmission pump using SI.

8. For vehicles with more than twenty miles (32 km) and no loss of functionality: Remove the transmission and inspect the transmission overdrive carrier assembly and thrust carrier/forward clutch bearing assembly and mating surfaces for heat distress or damage.

A. If no heat distress or damage is present: Replace the overdrive carrier assembly and thrust carrier/forward clutch bearing assembly. The Front End Play Check must be performed if the overdrive carrier assembly and thrust carrier/forward clutch bearing assembly is replaced. The Pump Repair Procedure must also be performed. Perform the Pump Repair Procedure and reassemble the transmission. Use SI to disassemble and reassemble the transmission.

B. If major heat distress or damage is detected in additional components, replace the transmission. Use SI to remove and install the transmission.

9. If the transmission has lost functionality, replace the transmission, Use SI to remove and install the transmission.

Pump Repair Procedure





1. Remove the cup plug from the pump cover front lube hole.





2. Insert the aluminum pin plug (plug kit P/N 24232339) into the front lube hole. Seat the pin flush or 1/16" below the pump cover outer diameter.





3. Using a chisel point tool, stake the aluminum pin in a cross pattern.





4. Verify that the installed plug does not protrude past the pump cover outer diameter or move under light pressure.