Buick Encore: Repair instructions - on vehicle

Manual shift detent lever with shaft position witch assembly replacement

Special Tools

DT-41229 Manual Shaft Pin Installer

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (2H0) , Engine Coolant Fan Shroud Replacement (LUJ, LUV) .
2. Remove the automatic transmission range selector lever. Refer to Automatic Transmission Range Selector Lever Replacement.
3. Remove the control valve body. Refer to Control Valve Body Replacement.

Fig. 1: View Of Manual Shift Detent Lever & Shaft Position Switch Assembly

4. Remove the manual shaft detent lever hub pin (1) using a pry bar and pliers.
5. Remove and DISCARD the manual shift shaft pin (5).
6. Remove the manual shaft (2).

NOTE: Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case.

7. Remove the manual shaft detent (with shift position switch) lever assembly (4).

Installation Procedure

Fig. 2: Identifying Manual Shaft Detent (W/Shift Position Switch) Lever Assembly

NOTE: Connect the actuator rod (3) to the detent lever assembly.

1. Install the manual shaft detent (with shift position switch) lever assembly (4).
2. Install the manual shaft (2).
3. Install the manual shaft detent lever hub pin (1).

Specification

Install the manual shaft detent lever hub pin to height of 7.9 mm (0.38 in) (b).

CAUTION: Use J 41229 to install the manual shaft pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack.

4. Install the NEW manual shift shaft pin (5) using DT-41229 pin installer. Use a NEW pin to ensure proper engagement with the case.

Specification

Inspect pin installed height is within 7.2-8.2 mm (0.28-0.32 in) (a).

5. Install the control valve body. Refer to Control Valve Body Replacement.
6. Install the automatic transmission range selector lever. Refer to Automatic Transmission Range Selector Lever Replacement.
7. Install the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement (2H0) , Engine Coolant Fan Shroud Replacement (LUJ, LUV) .
8. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn .

TRANSMISSION CONTROL LEVER KNOB REPLACEMENT

The transmission control lever knob is not serviceable separately. Refer to Transmission Control Replacement.

TRANSMISSION CONTROL REPLACEMENT

Fig. 3: Transmission Control Assembly

Transmission Control Replacement

Automatic transmission range selector lever replacement

Removal Procedure

1. Set the park brake and chock the wheels.

Fig. 4: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin

2. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.
3. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket.

Fig. 5: View Of Transmission Range Selector Lever

WARNING: Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position.

4. Remove the transmission range selector lever nut (1).
5. Remove the transmission range selector lever (2).

Installation Procedure

Fig. 6: View Of Transmission Range Selector Lever

WARNING: Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position.

1. Install the transmission range selector lever (2).

CAUTION: Refer to Fastener Caution .

2. Install the transmission range selector lever nut (1) and tighten to 30 (22 lb ft).

Fig. 7: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin

3. Install the transmission range selector lever cable (2) to the cable bracket.
4. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.
5. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment.

RANGE SELECTOR LEVER CABLE REPLACEMENT

Removal Procedure

1. Set the park brake and chock the wheels.

Fig. 8: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin

2. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.
3. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket.
4. Remove the front floor console stowage tray. Refer to Front Floor Console Stowage Tray Replacement (Encore) , Front Floor Console Stowage Tray Replacement (Encore) .

Fig. 9: Cable Terminal And Cable Retainer

5. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin.
6. Release the transmission range selector lever cable retainer (1) and remove the transmission range selector cable from the transmission control lever base.

Fig. 10: Gear Shift Cable Grommet & Fasteners

7. Move the floor carpet in order to gain access to the gear shift cable grommet (2).
8. Remove the grommet fasteners (1) and the transmission range selector lever cable grommet from the cowl panel.
9. Remove the transmission range selector lever cable from the vehicle.

Installation Procedure

1. Install the transmission range selector lever cable to the vehicle.

Fig. 11: Gear Shift Cable Grommet & Fasteners

2. Install the transmission range selector lever cable grommet to the cowl panel.

CAUTION: Refer to Fastener Caution .

3. Install the grommet fasteners (2) and tighten to 9 (80 lb in).

Fig. 12: Cable Terminal And Cable Retainer

4. Install the transmission range selector lever cable to the transmission control lever base. Insure the cable retainer (1) is fully secured to the transmission control lever base.
5. Connect the transmission range selector lever cable terminal (2) to the shift lever pin.
6. Install the front floor console stowage tray. Refer to Front Floor Console Stowage Tray Replacement (Encore) , Front Floor Console Stowage Tray Replacement (Encore) .

Fig. 13: Automatic Transmission Range Selector Lever Cable Terminal And Shift Lever Pin

7. Install the transmission range selector lever cable (2) to the cable bracket.
8. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.
9. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment.

Range selector lever cable adjustment

NOTE: Adjust the automatic transmission range selector cable while the transmission and the gear selector are in the Park position only. Failure to do so may cause mis-adjustment.

1. Set the park brake and chock the wheels.
2. Verify the transmission range select lever is in the park position.
3. Verify the transmission manual shift lever is in the park position.

Fig. 14: Cable Tube & Adjuster Clip

4. Release the range select cable adjuster clip (1).

Fig. 15: Cable Tube & Adjuster Clip

5. Depress the adjuster clip (1) locking the adjuster clip completely.
6. Ensure the cable tube (2) is secure.
7. Check the transmission range select lever in all gear selections for proper operation.

RANGE SELECTOR LEVER CABLE BRACKET REPLACEMENT

Removal Procedure

1. Set the park brake and chock the wheels.
2. Remove the battery tray. Refer to Battery Tray Replacement .

Fig. 16: Range Selector Lever Cable

3. Disconnect the range selector cable end (1) from the range selector lever.
4. Disconnect the range selector cable (2) from the range selector cable bracket.

Fig. 17: Range Selector Cable Bracket And Bolts

5. Remove the transmission range selector cable bracket bolts (1).
6. Remove the transmission range selector cable bracket (2).

Installation Procedure

Fig. 18: Range Selector Cable Bracket And Bolts

1. Install the transmission range selector cable bracket (2).

CAUTION: Refer to Fastener Caution .

2. Install the transmission range selector cable bracket bolts (1) and tighten to 22 (16 lb ft).

Fig. 19: Range Selector Lever Cable

3. Connect the range selector cable (2) to the range selector cable bracket.
4. Connect the range selector cable end (1) to the range selector lever.
5. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment.
6. Install the battery tray. Refer to Battery Tray Replacement .

Transmission fluid drain and fill

Removal Procedure

Fig. 20: Identifying Fluid Level Hole Plug

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the front compartment front center insulator, if equipped. Refer to Front Compartment Front Center Insulator Replacement .
3. Remove the fluid drain plug (1).
4. Drain transmission fluid into a suitable container.

CAUTION: Refer to Component Fastener Tightening Caution .

5. Install the fluid drain plug (1) and tighten to 12 (106 lb in).

Installation Procedure

Fig. 21: Identifying Fluid Fill Cap

1. Lower the vehicle.
2. Remove the fluid fill cap (1).
3. Fill the transmission to the proper level with the correct fluid. Refer to Transmission Fluid Level and Condition Check , and Fluid Capacity Specifications (6T40/45/50) .
4. Install the front compartment front center insulator, if equipped. Refer to Front Compartment Front Center Insulator Replacement .
5. Install the fluid fill cap (1).

AUTOMATIC TRANSMISSION FLUID PRESSURE TEST HOLE PLUG REPLACEMENT

Fig. 22: Identifying Pressure Test Plug

Automatic Transmission Fluid Pressure Test Hole Plug Replacement

FRONT WHEEL DRIVE SHAFT SEAL REPLACEMENT - LEFT SIDE

Fig. 23: Identifying Left Front Wheel Drive Shaft Seal

Front Wheel Drive Shaft Seal Replacement - Left Side

FRONT WHEEL DRIVE SHAFT SEAL REPLACEMENT - RIGHT SIDE (AWD)

Removal Procedure

1. Remove the transfer case. Refer to Transfer Case Replacement

Fig. 24: Transfer Case-To-Transfer Case Bracket Seal

2. Remove and discard the transfer case-to-transfer case bracket seal (1).

Installation Procedure

Fig. 25: Transfer Case-To-Transfer Case Bracket Seal

1. Clean the contact surfaces between the transfer case and the transfer case bracket.

NOTE: Install the OD groove of the seal onto the raised area in the adapter seal bore. A properly installed seal will be installed 2.66 mm (0.10 in) below the machined surface when measured from the bushing alignment mark side of the adapter.

2. Install a new transfer case-to-transfer case bracket seal (1). Refer to Transfer Case Identification .
3. Install the transfer case. Refer to Transfer Case Replacement .

FRONT WHEEL DRIVE SHAFT SEAL REPLACEMENT - RIGHT SIDE (FWD)

Fig. 26: Identifying Right Front Wheel Drive Shaft Seal

Front Wheel Drive Shaft Seal Replacement - Right Side (FWD)

Manual shift shaft and seal replacement

Special Tools

• DT-45201 Cooler Line Seal Remover
• DT-49101 Seal Installer

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Remove the manual shaft and position switch assembly. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement.

Fig. 27: Identifying Seal Removal Tool

3. Remove the manual shaft seal (1) using DT-45201 remover.

Installation Procedure

1. Install the manual shaft and position switch assembly. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement.

Fig. 28: Identifying Seal Installation Tool

2. Install the manual shaft seal (1) using DT-49101 seal installer.
3. Install the battery tray. Refer to Battery Tray Replacement .

CONTROL SOLENOID VALVE AND TRANSMISSION CONTROL MODULE ASSEMBLY REPLACEMENT

Removal Procedure

1. Remove the transmission control valve body cover. Refer to Control Valve Body Cover Replacement.

Fig. 29: Identifying Input Speed Sensor Electrical Connector

2. Disconnect the output speed sensor electrical connector (2).
3. Disconnect the shift position switch electrical connector (3).
4. Disconnect the input speed sensor electrical connector (1).

Fig. 30: Locating Control Valve Body & Bolts

5. Remove the 3 control solenoid valve assembly bolts (1) M5 x 40.5.
6. Remove the 12 control solenoid valve assembly bolts (2) M6 x 97.
7. Remove the control solenoid valve assembly with transmission control module (3).

CAUTION: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination.

8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable.
9. Inspect the pressure switch seals for damage or contamination. Replace the control solenoid valve assembly as necessary.
10. Inspect the channel plate bolt pass through holes for damage or burnelling. Any damage could cause leaking. Replace as necessary.

Installation Procedure

Fig. 31: Locating Control Valve Body & Bolts

CAUTION: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination.

1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals.
2. Install the control solenoid valve assembly with transmission control module (3).
3. Hand start the control valve body bolts (1, 2).

Fig. 32: Identifying Control Valve Body Bolt Tightening Sequence

CAUTION: Refer to Fastener Caution .

4. Secure the 12 control solenoid valve assembly bolts (2) M6 x 97 and tighten in sequence to 12 (106 lb in).
5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 7 (62 lb in).

Fig. 33: Identifying Input Speed Sensor Electrical Connector

6. Connect the input speed sensor electrical connector (1).
7. Connect the output speed sensor electrical connector (2).
8. Install the transmission control valve body cover. Refer to Control Valve Body Cover Replacement.
9. After repairs, refer to Control Module References for programming and set up procedures.
10. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn .

Control valve body cover replacement

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower Cover Replacement (Encore) .
4. Remove the left front wheel house liner. Refer to Front Wheelhouse Liner Replacement (Encore) , Front Wheelhouse Liner Replacement (Encore) .
5. Drain the transmission fluid.
6. Disconnect the transmission fluid cooler inlet pipe from the transmission. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
7. Disconnect the transmission fluid cooler outlet pipe from the transmission Refer to Transmission Fluid Cooler Outlet Pipe Replacement .

Fig. 34: Identifying Control Valve Body Transmission Control Module (TCM) Electrical Connector

8. Disconnect the control valve body transmission control module electrical connector (1), then unclip the wiring harness from the cover.

Fig. 35: View Of Control Valve Body

9. Remove the control valve body cover bolts (1).
10. Remove the control valve body cover (2).
11. Remove the control valve body cover gasket (3).

CAUTION: Support the control solenoid valve assembly around the connector when removing the seal. Excessive pulling force can damage the internal electrical connections.

12. Remove the control valve body cover wiring connector hole seal (4).
13. Remove all traces of the old gasket material. Clean the transmission case and control valve body cover gasket surfaces.

Installation Procedure

Fig. 36: View Of Control Valve Body

1. Install the control valve body cover wiring connector hole seal (4).
2. Install the control valve body cover gasket (3) to the control valve body cover.
3. Install the control valve body cover (2).
4. Hand start the control valve body cover bolts (1).

Fig. 37: Identifying Valve Body Cover Bolt Tightening Sequence

CAUTION: Refer to Fastener Caution .

NOTE: Install all control valve body cover bolts and studs by hand then torque all bolts and studs in sequence.

5. Install the control valve body cover bolts. Tighten the bolts in sequence to 12 (106 lb in).

Fig. 38: Identifying Control Valve Body Transmission Control Module (TCM) Electrical Connector

6. Connect the control valve body transmission control module electrical connector (1), then clip the wiring harness to the cover.
7. Raise the vehicle.
8. Connect the transmission fluid cooler outlet pipe to the transmission Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
9. Connect the transmission fluid cooler inlet pipe to the transmission. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
10. Install the left front wheel house liner. Refer to Front Wheelhouse Liner Replacement (Encore) , Front Wheelhouse Liner Replacement (Encore) .
11. Install the front bumper fascia opening lower cover. Refer to Front Bumper Fascia Opening Lower Cover Replacement (Encore) .
12. Fill the transmission with correct fluid.
13. Check transmission fluid level. Refer to Transmission Fluid Level and Condition Check .
14. Lower the vehicle.
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Check for leaks.

CONTROL VALVE BODY REPLACEMENT

Fig. 39: View Of Control Valve Body

Control Valve Body Replacement

OUTPUT SPEED SENSOR REPLACEMENT

Fig. 40: Identifying Output Speed Sensor

Output Speed Sensor Replacement

INPUT SPEED SENSOR REPLACEMENT

Removal Procedure

1. Remove the control valve body. Refer to Control Valve Body Replacement.

Fig. 41: Identifying Input Speed Sensor Mounting Bolt

2. Remove the input speed sensor bolt (2) M6 x 23.
3. Unlock the 2 retaining tabs inside the transmission housing.
4. Remove the input speed sensor (3).
5. Remove the 3 input speed sensor seals (1).

Installation Procedure

Fig. 42: Identifying Input Speed Sensor Mounting Bolt

1. Install the 3 input speed sensor seals (1).
2. Install the input speed sensor (3).
3. Verify that the retaining tabs are locked completely.

CAUTION: Refer to Fastener Caution .

4. Install the input speed sensor bolt (2) M6 x 23 and tighten to 9 (80 lb in).
5. Install the control valve body. Refer to Control Valve Body Replacement.
6. Perform the transmission adaptive values learn procedure. Refer to Transmission Adaptive Values Learn .

Transmission mount bracket replacement -REAR (AWD)

Removal Procedure

1. Remove the transfer case. Refer to Transfer Case Replacement .

Fig. 43: Transmission Bracket Fasteners

2. Remove and DISCARD the five transmission bracket fasteners (1, 2).

Fig. 44: Transmission Bracket And Through Bolt

3. Remove and DISCARD the rear transmission mount through bolt (1).
4. Remove the transmission bracket (2) from the transmission.

Installation Procedure

Fig. 45: Transmission Bracket And Through Bolt

1. Install the transmission bracket (2) to the transmission.
2. Install the NEW rear transmission through bolt (1). Do not tighten at this time.

Fig. 46: Transmission Bracket Fasteners

CAUTION: Refer to Fastener Caution .

3. Install the NEW transmission bracket to transmission fasteners (1) and tighten to 100 (74 lb ft) plus 30-40 degrees.
4. Install the NEW transmission bracket to transmission fastener (2) and tighten to 60 (44 lb ft) plus 60-75 degrees.

Fig. 47: Transmission Bracket And Through Bolt

5. Install the NEW rear transmission mount through bolt (1) and tighten to 80 (59 lb ft) plus 45-60 degrees.
6. Install the transfer case. Refer to Transfer Case Replacement

TRANSMISSION MOUNT BRACKET REPLACEMENT - REAR (FWD)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
3. Using a suitable jack stand, support the rear of the transmission.

Fig. 48: Rear Transmission Mount Bracket To Rear Mount Through Bolt

4. Remove and DISCARD the rear transmission mount bracket to rear mount through bolt (1).

Fig. 49: Transmission Mount Bracket To Transmission Bolts

5. Remove and DISCARD the 4 rear transmission mount bracket to transmission bolts (1).
6. Remove the rear transmission mount bracket (2).

Installation Procedure

Fig. 50: Transmission Mount Bracket To Transmission Bolts

1. Install the rear transmission mount bracket (2).

CAUTION: Refer to Fastener Caution .

2. Install the 4 NEW rear transmission mount bracket to transmission bolts (1) and tighten to 100 (74 lb ft) plus 30-45 degrees.

Fig. 51: Rear Transmission Mount Bracket To Rear Mount Through Bolt

3. Install the NEW rear transmission mount bracket to rear mount through bolt (1) and tighten to 80 (59 lb ft) plus 45-60 degrees.
4. Remove the jack stand.
5. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
6. Lower the vehicle.

Transmission mount replacement - left side

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement .

Fig. 52: Electronic Vacuum Pump (EVP)

2. Disconnect the electrical connector (1) from the Electronic Vacuum Pump (EVP) (3).
3. Remove the two EVP fasteners (2).
4. Position the EVP out of the way.
5. Install the engine support fixture.

Fig. 53: Left Transmission Mount

6. Remove the shift cable bracket to transmission mount bolt (4).

NOTE: Do Not remove the shift cable bracket bolt.

7. Loosen the shift cable bracket bolt (5).
8. Remove and DISCARD the left transmission mount to bracket bolts (1).
9. Remove the left transmission mount to body bolts (2).
10. Remove the left transmission mount to body nut (3).
11. Remove the transmission mount (6) from the vehicle.

Installation Procedure

Fig. 54: Left Transmission Mount

1. Install the left transmission mount (6) to the vehicle.

CAUTION: Refer to Fastener Caution .

2. Install the transmission mount to body bolts (2) and tighten to 58 (43 lb ft).
3. Install the transmission mount to body nut (3) and tighten to 58 (43 lb ft).
4. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 (37 lb ft) plus 60-75 degrees.
5. Install the shift cable bracket to transmission mount bolt (4) and tighten to 22 (16 lb ft).
6. Tighten the shift cable bracket bolt (5) to 22 (16 lb ft).
7. Remove the engine support fixture.

Fig. 55: Electronic Vacuum Pump (EVP)

8. Reposition the EVP (3) to the transmission mount.
9. Install the EVP to transmission mount nuts (2) and tighten to 22 (16 lb ft).
10. Connect the electrical connector (1) to the EVP (3).
11. Install the battery tray. Refer to Battery Tray Replacement .

TRANSMISSION REAR MOUNT REPLACEMENT (AWD)

Removal Procedure

1. Remove the transfer case. Refer to Transfer Case Replacement .

Fig. 56: Transmission Bracket Fasteners

2. Remove and DISCARD the five transmission bracket fasteners (1, 2).

Fig. 57: Transmission Bracket And Through Bolt

3. Remove and DISCARD the rear transmission mount through bolt (1).
4. Remove the transmission bracket (2) from the transmission.

Fig. 58: Transmission Rear Mount

5. Remove and DISCARD the transmission rear mount fastener (2).
6. Remove the transmission rear mount (1) from the vehicle.

Installation Procedure

Fig. 59: Transmission Rear Mount

1. Install the transmission rear mount (1) to the vehicle.

Fig. 60: Transmission Bracket And Through Bolt

2. Install the transmission bracket (2) to the transmission.

Fig. 61: Transmission Bracket Fasteners

CAUTION: Refer to Fastener Caution .

3. Install the NEW transmission bracket to transmission fasteners (1) and tighten to 100 (74 lb ft) plus 30-40 degrees.
4. Install the NEW transmission bracket to transmission fastener (2) and tighten to 60 (44 lb ft) plus 60-75 degrees.

Fig. 62: Transmission Rear Mount

5. Install the NEW transmission rear mount fastener (2) and tighten to 100 (75 lb ft) plus 90 - 105 degrees.

Fig. 63: Transmission Bracket And Through Bolt

Install the New rear transmission mount through bolt (1) and tighten to 80 (59 lb ft) plus 45-60 degrees.

Install the transfer case. Refer to Transfer Case Replacement

TRANSMISSION REAR MOUNT REPLACEMENT (FWD)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 64: Rear Transmission Mount Bracket To Rear Mount Through Bolt

2. Remove and DISCARD the rear transmission mount bracket to rear mount through bolt (1).
3. Remove and DISCARD the rear transmission mount bracket to transmission bolts (2).
4. Remove the rear transmission mount bracket.
5. Remove and DISCARD the rear transmission mount to frame bolt (3).
6. Remove the rear transmission mount.

Installation Procedure

Fig. 65: Rear Transmission Mount Bracket To Rear Mount Through Bolt

1. Install the rear transmission mount.

CAUTION: Refer to Fastener Caution .

2. Install the NEW rear transmission mount to frame bolt (3) and tighten to 100 (74 lb ft) plus 90 - 105 degrees.
3. Install the rear transmission mount bracket.
4. Install the NEW rear transmission mount bracket to transmission bolts (2) and tighten to 100 (74 lb ft) plus 30-45 degrees.
5. Install the NEW rear transmission mount bracket to rear mount through bolt (1) and tighten to 80 (59 lb ft) plus 45-60 degrees.
6. Lower the vehicle.

Transmission replacement

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement .
2. Remove the front bumper fascia opening upper cover. Refer to Front Bumper Fascia Opening Upper Cover Replacement .
3. Without draining the coolant or removing the hoses, remove and position aside the radiator surge tank.

   Refer to Radiator Surge Tank Replacement (LUV, 2H0, LUJ) .

4. Remove the transmission range selector lever cable. Refer to Range Selector Lever Cable Replacement.
5. Remove the power brake booster pump assembly, if equipped. Refer to Power Brake Booster Pump Replacement .

Fig. 66: Identifying Control Valve Body Transmission Control Module (TCM) Electrical Connector

6. Disconnect the control valve body transmission control module electrical connector (1) then unclip the connector from the transmission.
7. Remove the transmission fluid cooler inlet hose from the transmission. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
8. Remove the transmission fluid cooler outlet hose from the transmission. Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
9. Plug and/or cap the pipes and transmission to prevent contamination.

Fig. 67: Upper Transmission To Engine Bolts

10. Remove the upper transmission to engine bolts (2).
11. Install the support fixture.

Fig. 68: Identifying Fluid Level Hole Plug

12. Drain the transmission fluid. Refer to Transmission Fluid Drain and Fill.
13. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
14. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
15. Remove the front wheel drive shafts from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side , and Front Wheel Drive Shaft Replacement - Right Side .
16. On FWD vehicles, remove the intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement (LUV with MH8 or MH5) .
17. On AWD vehicles, remove the transfer case. Refer to Transfer Case Replacement .
18. Remove the rear transmission mount bracket from the transmission. Refer to Transmission Mount Bracket Replacement - Rear (AWD), Transmission Mount Bracket Replacement - Rear (FWD).
19. Remove the starter motor. Refer to Starter Replacement (LUV) , Starter Replacement (2H0) .

Fig. 69: Flywheel Bolts And Hole Cover

20. Mark the relationship of the flywheel to the torque converter for reassembly.
21. Remove the hole cover (1) and the three torque converter to flywheel fasteners (2).

Fig. 70: Left Transmission Mount

22. Remove the left transmission mount (6). Refer to Transmission Mount Replacement - Left Side.
23. Use a transmission jack in order to support the transmission.

Fig. 71: Upper Transmission To Engine Bolts

34. Remove the lower transmission fasteners (1, 3, 4, 5).

NOTE: Ensure the torque converter remains securely in place on the transmission input shaft while separating and removing the transmission.

25. Separate the transmission from the engine.
26. Lower the transmission with the transmission jack far enough to remove the transmission.
27. Flush and flow test the transmission oil cooler and lines. Refer to Transmission Fluid Cooler Flushing and Flow Test .

Installation Procedure

1. Raise the transmission with the transmission jack and position the transmission to the engine.

Fig. 72: Upper Transmission To Engine Bolts

CAUTION: Refer to Fastener Caution .

2. Install the transmission bolts (3, 4) and tighten to 60 (44 lb ft).
3. Install the transmission bolts (5) and the transmission nut (1) and tighten to 40 (30 lb ft).
4. Remove the transmission jack.

Fig. 73: Left Transmission Mount

5. Install the left transmission mount (6). Refer to Transmission Mount Replacement - Left Side.

Fig. 74: Flywheel Bolts And Hole Cover

NOTE: If reusing the torque converter bolts, clean the threads and apply threadlocker to the threads prior to installation.

6. Install the torque converter to flywheel bolts (2) and tighten to 60 (44 lb ft) and install the hole cover (1).
7. Install the starter motor. Refer to Starter Replacement (LUV) , Starter Replacement (2H0) .
8. Install the rear transmission mount bracket to the transmission. Refer to Transmission Mount Bracket Replacement - Rear (AWD), Transmission Mount Bracket Replacement - Rear (FWD).
9. On AWD vehicles, install the transfer case. Refer to Transfer Case Replacement .
10. On FWD vehicles, install the intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement (LUV with MH8 or MH5) .
11. Install the front wheel drive shafts to the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side , and Front Wheel Drive Shaft Replacement - Right Side .
12. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (Long Cradle) , Drivetrain and Front Suspension Frame Replacement (Short Cradle) .
13. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement (LUV) , Exhaust Front Pipe Replacement .
14. Remove the support fixture.

Fig. 75: Upper Transmission To Engine Bolts

15. Install the upper transmission to engine bolts (2) and tighten to 60 (44 lb ft).

Fig. 76: Identifying Control Valve Body Transmission Control Module (TCM) Electrical Connector

16. Connect the control valve body transmission control module electrical connector (1) then clip the connector to the transmission.
17. Install the transmission fluid cooler outlet hose to the transmission. Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
18. Install the transmission fluid cooler inlet hose to the transmission. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
19. Install the power brake booster pump assembly, if equipped. Refer to Power Brake Booster Pump Replacement .
20. Install the transmission range selector lever cable. Refer to Range Selector Lever Cable Replacement.
21. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment.
22. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (LUV, 2H0, LUJ) .
23. Install the front bumper fascia opening upper cover. Refer to Front Bumper Fascia Opening Upper Cover Replacement .
24. Install the battery tray. Refer to Battery Tray Replacement .
25. Fill the transmission with fluid. Refer to Transmission Fluid Drain and Fill.
26. If a NEW transmission control module (TCM) has been installed into the vehicle, the NEW module needs to be reprogrammed.

NOTE:

The transmission adaptive values learn procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set:

• Transmission internal service/overhaul
• Valve body repair or replacement
• Control solenoid valve assembly replacement
• TCM software/calibration update
• Any service in response to a shift quality concern

27. Perform the transmission adaptive values learn. Refer to Transmission Adaptive Values Learn .
28. Road test the vehicle.

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