Corrective Action

Replace the Separator Plate Gaskets and use the increased torque specification for the main case bolts.

1. Reinstall the oil pans with the original gaskets.

2. Remove the transmission from the vehicle (4WD recommendation: remove the transfer case before removing the transmission). Refer to service manual.

3. Clean the outside of the transmission.

4. Attach the holding fixture to the transmission, Special Tool P/N J-8763-02 (Trans Holding Fixture) & J-3289-20 (Base). Secure the transmission with the input shaft pointing up.

NOTE:
To avoid damaging transmission do not over tighten the holding fixture.

5. Place an oil catch pan under the transmission.

6. Slide the torque converter off the transmission. Avoid damaging the pilot by carefully setting the converter on the bench with the opening up.

7. Remove the oil pans.

8. Remove the adapter case harness.





9. Remove the turbine shaft 0-ring and discard it (see figure 1).





10. Remove the seven case housing bolts at the outer ring, not the 5 inner bolts (see figure 2).





11. Lift the converter housing and oil pump assembly straight up. Set the assembly on the bench with the pump side up (see figure 3).





12. Replace the case 0-ring and gasket (8-96017-189-0 0-ring & 8-96014-973-0 gasket) (see figure 4).





13. Wet the new gasket and 0-ring with DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin 1B03-05-S001 4L30E/4L60E Transmission Fluid) (see figure 5).

14. Line-up the case holes with the gasket and install the 0-ring without twisting it.

15. Use ONLY petroleum jelly to hold the selective thrust washer in place.





16. Replace the turbine shaft scarf-cut plastic seals (8-96017-484-0 scarf seals 2x) (see figure 6).

17. Apply petroleum jelly in the seal groves to hold the new seals in place.

Note:
Be sure the angled cut ends are properly matched or the new seals will not seal properly.





18. Grab the turbine shaft and lift out the 4th clutch, 4th retainer, & overrun assembly (Figure 7).





19. Remove the remaining steel 4th clutch plate (see figure 8).





20. Remove the overdrive internal gear and thrust bearing (see figure 9).

21. Remove the thrust washer





22. Lift the adapter case off the main case (see figure 10).





23. Remove the selective washer from the center support housing (see figure 11).





24. Remove two oil passage 0-rings from the main case and discard them (see figure 12).

25. Install two oil passage 0-rings on the main case (8-96014-270-0 0-Ring, Case Drain Back 2x). Lube them with DEXR0N(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-S001 4L30E/4L60E Transmission Fluid) (see figure 12).





26. Compress the reverse spring seat with Special Tool P/N J-23327 (Reverse Spring Seat Compressor) (see figure 13).





27. Remove and discard the retaining (snap) ring (see figure 14).

28. Remove the compressor tool and spring seat. Discard the spring seat.





29. Remove the reverse piston. Discard the inner & outer 0-rings (see figure 15).

30. Remove the center support bolts.





31. Remove the center support housing from the adapter case (see figure 16).

32. Use a plastic hammer if necessary.

IMPORTANT:
The separator plate gaskets will look deformed and are the primary internal leak. If both gaskets are flat, in-place and not torn STOP, replacing them will not repair the complaint.

NOTE:
Follow normal transmission replacement procedure for warrantable cases.





33. Replace the separator plate gaskets (8-96016-514-0 gasket 2x) (see figure 17 & 18).





34. Be sure the oil restrictor is in the correct location (see figure 19).

35. Stack the gasket, separator plate, gasket, center support on the adapter case (see figure 10).

36. Use the two 9 inch guide pins and the center support bolts to lineup the gaskets & plate, Special Tool P/N J-38588.

37. Reinstall the center support bolts. Torque to 25 N.m (18 lb-ft).





38. Install the inner & outer reverse piston 0-rings (8-96014-331-0 inner seal & 8-96014-332-0 outer seal). Lube them with DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-5001 4L30E/4L60E Transmission Fluid)) or petroleum jelly (see figure 20).

39. Reinstall the reverse piston. Tool is not required to guide the 0-rings (see figure 20).





40. Place the springs (24) on the piston. Replace damaged springs as needed (8-08958-719-0 spring) (see figure 21).

41. Install the new spring seat (8-05258-021-0) and compress the springs with the compressor, Special Tool P/N J-23327 (Reverse Spring Seat Compressor) (see figure 13).

42. Install the new retaining (snap) ring (8-05258-093-0) and remove the compressor.

43. Reinstall the selective washer with grease to hold it.

44. Install a new case 0-ring (8-96017-189-0). Lube it with DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-S001 4L30E/4L60E Transmission Fluid).





45. Install the two 9 inch guide pins, Special Tool P/N J-38588 (see figure 22).

46. Install the adapter case.





47. Reinstall the thrust washer, tangs toward the adapter case in their slots (see figure 23).

48. Lube the washer with DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-S001 4L30E/4L60E Transmission Fluid).

49. Reinstall the overdrive internal gear and thrust bearing. DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-S001 4L30E/4L60E Transmission Fluid) (see figure 9)

NOTE:
Thrust bearing outer case faces the internal gear.

50. Remove the 4th clutch & 4th retainer from the overrun assembly (see figure 8).





51. Reinstall the turbine shaft and overrun assembly (see figure 24).

52. Reinstall the 4th clutch; steel, lined, steel, steel, lined, steel (see figure 8).

53. The steel plates go in with the short tang towards the valve body.

54. Reinstall the 4th retainer, cutout notch facing up & toward the valve body (see figure 8).

55. Place the new gasket on the adapter case (see figure 4).

56. Lower the converter housing and oil pump assembly onto the adapter case (see figure 3).

57. Press the converter housing and oil pump assembly and case together by hand.





58. Install two of the seven housing bolts, hand tight (see figure 25).

59. Remove the two 9 inch guide pins (see figure 22).

60. Install the remaining housing bolts (seven total) and torque them to 54 N.m (40 lb-ft) in a cross pattern.

61. NOTE: This is an increased torque specification (see figure 25).

62. Install a new turbine shaft 0-ring (8-96013-953-0). Lube it with DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-S001 4L30E/4L60E Transmission Fluid).

63. Reinstall the adapter case harness. Torque the valve body bolt to 20 N.m (15 lb ft).

64. Install new oil pan gaskets without any sealer (8-96014-234-0 gasket, main & 8-96014-235-0 gasket, adapter).

65. Remove the transmission from the holding fixture and set it, pan down, on the bench.

66. Lubricate the oil pump seal and the converter sealing surface with DEXRON(R)-III with a G-License Number (G-XXXX) (refer to bulletin IB03-05-S001 4L30E/4L60E Transmission Fluid).

67. Slide the converter onto the transmission. Turn and push to align the turbine shaft, the stator shaft, and the oil pump. The converter must be completely inside the bellhousing.

68. Reinstall the transmission.

NOTE

1. The bellhousing bolt located two holes above the starter motor must be no longer than 40 mm. If a longer bolt is used, it will break into the engine coolant jacket.

2. Before installing the converter to the drive plate bolts, push the converter into the transmission and check the gap between the converter and drive plate. A 10 mm gap or more must exist otherwise the oil pump will be damaged when the engine is started. If the gap is too small, remove the transmission, then turn and push the converter to engage the pump.

69. Set the transmission fluid level. See appropriate Service Manual.

70. Test-drive the vehicle.