6R60 - Automatic Transaxle/Transmission

Transmission - Four Wheel Drive (4WD)








Installation
1. Install the special tool.





2. CAUTION: The converter housing is piloted into position by dowels in the rear of the engine block. The torque converter must rest squarely against the flexplate. This indicates that the converter pilot is not binding in the engine crankshaft.

Position and secure the transmission on the high-lift transmission jack. Raise and position the transmission into the vehicle.
3. Remove the special tool.





4. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the transmission to the engine.

With the transmission in a horizontal position, move it toward the engine. Align the orange balancing marks between the torque converter studs and the flexplate bolt holes.

5. NOTE: Install the 7 transmission-to-engine bolts in their correct locations noted during removal.

NOTE: The top 2 transmission-to-engine bolts need to be installed prior to installing the rest of the bolts.

Install the 7 transmission-to-engine bolts.
^ Tighten to 48 Nm (35 lb-ft).





6. Connect the main transmission electrical harness by pushing it in and twisting the outer shell to lock it in place.





7. Connect the wire harness to the top of the transmission.





8. Install the catalyst monitor sensor electrical connector to the LH side of the transmission.





9. Position the transmission fluid cooler tubes in place and install the transmission fluid cooler tube bracket nut.
^ Tighten to 12 Nm (9 lb-ft).





10. Connect the engine oil low level sensor electrical connector.





11. NOTE: Inspect the case to make sure that the old O-rings are not stuck in the case.

NOTE: Install new O-rings on the ends of the cooler lines prior to installing.

Install new O-rings on the transmission fluid cooler tubes.





12. Install the transmission fluid cooler tube bracket bolt.
^ Tighten to 25 Nm (18 lb-ft).





13. Install the starter motor and the 3 starter motor bolts.
^ Tighten to 26 Nm (19 lb-ft).





14. Install the ground wire on the stud and install the ground wire nut.
^ Tighten to 23 Nm (17 lb-ft).





15. Install the starter motor electrical connectors.
1 Tighten to 12 Nm (9 lb-ft).
2 Tighten to 6 Nm (53 lb-inch).





16. Install the plastic starter motor electrical connector cap.





17. Install 4 new torque converter nuts.
^ Tighten to 35 Nm (26 lb-ft).





18. Install the flexplate inspection cover and the inspection cover bolts.
^ Tighten to 35 Nm (26 lb-ft).





19. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs are locked in place and the selector lever cable end is snapped onto the ball stud. Press the selector lever cable into the bracket and listen for the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the selector lever cable 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 selector lever cable end is correctly installed.

Position the selector lever cable in place, install the selector lever cable bracket bolts and connect the selector lever cable end.
^ Tighten to 27 Nm (20 lb-ft).
^ Listen for the audible click.
^ Pull back on the selector lever cable to make sure that it is correctly installed.





20. Install selector lever cable shield.





21. Install the fuel line bracket bolt.
^ Tighten to 25 Nm (18 lb-ft).





22. Position the dual converter Y-pipe in place and install the dual converter Y-pipe bolts and new nuts.
^ Tighten to 40 Nm (30 lb-ft).





23. NOTE: LH shown, RH similar.

Install new LH and RH exhaust flange nuts.
^ Tighten to 40 Nm (30 lb-ft).





24. NOTE: LH shown, RH similar.

Connect the RH and LH heated oxygen sensors (HO2S) connectors and the catalyst monitor sensor electrical connectors.





25. Install the 4 RH side crossmember bolts and the nut.
^ Tighten the vertical bolts to 80 Nm (59 lb-ft).
^ Tighten the horizontal nut to 90 Nm (66 lb-ft).





26. Install the 4 LH side crossmember bolts and the nut.
^ Tighten the vertical bolts to 80 Nm (59 lb-ft).
^ Tighten the horizontal nut to 90 Nm (66 lb-ft).





27. If equipped, install the RH exhaust heat shield.
^ Tighten to 15 Nm (11 lb-ft).





28. Install the LH exhaust heat shield bolt.
^ Tighten to 15 Nm (11 lb-ft).





29. Install the transfer case.
30. Connect the battery ground cable.
31. Verify that the selector lever cable is correctly adjusted.
32. Reflash the transmission control module (TCM) to the latest level of software.
33. Using the transmission refill procedure, fill the transmission with clean transmission fluid.