Transmisión 6L80

2006 Chevrolet Corvette Z06
2006 TRANSMISSION Automatic Transmission - 6L80 - Overhaul - Corvette
2006 TRANSMISSION
Automatic Transmission - 6L80 - Overhaul - Corvette
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Ref No. Quantity Size Metric English
Case Extension Stud to
17 2 M10x1.5 15 N.m 11 lb ft
Case Extension
Case Extension to Case
16 6 M10x1.5x40 50 N.m 37 lb ft
Assembly
Control Solenoid Valve
Assembly and Control
Valve Lower Body
310 6 M5x0.8x55 8 N.m 71 lb in
Assembly to Control
Valve Upper Body
Assembly
Assembly and Control
Valve Lower Body
309 10 M5x0.8x45 8 N.m 71 lb in
Assembly to Control
Valve Upper Body
Assembly
312 2 M5x0.8x53 8 N.m 71 lb in
Heat Sink to Valve Body
Control Valve Upper
Body Assembly to
301 12 M5x0.8x36 8 N.m 71 lb in
Control Valve Lower
Body Assembly
Control (with Body and
Valve) Valve Assembly to 22 6 M5x0.8x73 8 N.m 71 lb in
Case Assembly
Fluid Pan Assembly to
30 18 M6x1.0x20 9 N.m 80 lb in
Case Assembly
Trans Oil Level Check
Plug to Fluid Pan 31 1 M12x1.75 25 N.m 18 lb ft
Assembly
Fluid Pump Cover
Assembly to Torque 231 13 M6 1.0x40 11 N.m 97 lb in
Converter Housing
Input and Output Speed
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07:12:01 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
Sensor Assembly to
Control Valve Upper 302 2 M6x1.0x20 12 N.m 106 lb in
Body Assembly
Line Pressure Test Hole
Plug to Torque Converter 202 1 1/8-27 NPTF 11 N.m 97 lb in
Housing
Manual Shaft Detent
23 1 M6x1.0x14.5 12 N.m 106 lb in
Assembly to Valve Body
Torque Converter
Housing Assembly to 3 9 M10x1.5x50 72 N.m 53 lb ft
Case Assembly
*Reference number refers to the component callout number in Disassembled Views
TRANSMISSION GENERAL SPECIFICATIONS
Transmission General Specifications

Name 6L80
RPO Codes MYC
Production Location Ypsilanti, Michigan (USA)
Transmission Drive Rear Wheel Drive
1st Gear Ratio 4.027
2nd Gear Ratio 2.364
3rd Gear Ratio 1.532
4th Gear Ratio 1.152
Reverse 3.064
Torque Converter Size - Diameter of Torque
258/300 mm
Converter Turbine
Pressure Taps Line Pressure
Transmission Fluid Type DEXRON VI®
Transmission Type: 6 Six Forward Gears
Transmission Type: L Longitude Mount
Transmission Type: 80 Product Series
Position Quadrant P, R, N, D, S (some models)
Case Material Die Cast Aluminum
Transmission Net Weight - Approximate 100 kg (220 lb)
Maximum Trailer Towing Capacity Refer to applicable owner's manual
FLUID CAPACITY SPECIFICATIONS
Fluid Capacity Specifications

Specification
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Application Metric English

Pan Removal - Approximate Capacity 6.2 liters 6.5 quarts
Overhaul - Approximate Capacity (STSV/XLRV) 9.5 liters 10 quarts
Overhaul - Approximate Capacity (Corvette) 11.8 liters 12.5 quarts
Complete Trans System Fluid Capacity (STSV) 10.01 liters 10.58 quarts
Complete Trans System Fluid Capacity (XLRV) 10.32 liters 10.91 quarts
Complete Trans System Fluid Capacity (Corvette) 12.53 liters 13.24 quarts
FLUID PUMP SELECTIVE SPECIFICATIONS
Fluid Pump Selective Specifications

Size Classification Thickness (mm) Thickness (in)
IMPORTANT:
Rotor and slide must be chosen from the same size classification as the oil pump body.
Allowable rotor and slide to fluid pump body end play is as follows:
Specification:
Slide to Fluid Pump Body End Play - 0.020-0.051 mm (0.0008-0.0020 in)
Rotor to Fluid Pump Body End Play - 0.020-0.051 mm (0.0008-0.0020 in)
The fluid pump assembly has selective rotor and slide components. These components are chosen based
on pump body dimensions. Fluid pump rotor and slide components are available in three size
classifications (1, 2, 3) with the following tolerances:
Rotor Selection
1 17.948-17.961 0.7066-0.7071
2 17.961-17.974 0.7071-0.7076
3 17.974-17.987 0.7076-0.7081
Slide Selection
1 17.948-17.961 0.7066-0.7071
2 17.961-17.974 0.7071-0.7076
3 17.974-17.987 0.7076-0.7081
Fluid Pump Body Depth
1 17.98-17.994 0.7079-0.7084
2 17.994-18.007 0.7084-0.7089
3 18.007-18.033 0.7089-0.7100
CLUTCH BACKING PLATE RETAINING RING SPECIFICATIONS
3-5 Reverse Clutch

Clutch Pack Travel Specification - 1.21-1.79 mm (0.048-0.070 in)
Retaining Ring Thickness
Metric English O.D. Color
IMPORTANT:
After measuring clutch pack travel, determine if the measurement is within the specification. If the
measurement is not within the specification, measure the thickness of the existing retaining ring,
and then choose a thicker or thinner retaining ring that will bring the measurement within
specification.
1.61-1.71 mm 0.063-0.067 in Gray
1.88-1.98 mm 0.074-0.078 in Light Green
2.15-2.25 mm 0.085-0.089 in Yellow
2.42-2.52 mm 0.095-0.099 in None
2.69-2.79 mm 0.106-0.110 in Purple
1-2-3-4 Clutch
IMPORTANT:
specification.
2.15-2.25 mm 0.085-0.089 in Yellow
2.42-2.52 mm 0.095-0.099 in None
2.69-2.79 mm 0.106-0.110 in Purple
2.96-3.06 mm 0.117-0.120 in Light Blue
3.23-3.33 mm 0.127-0.131 in Orange
4-5-6 Clutch
IMPORTANT:
specification.
1.60-1.70 mm 0.063-0.067 in Yellow
2.02-2.12 mm 0.080-0.083 in None
2.44-2.54 mm 0.096-0.100 in Purple
COMPONENT LOCATOR
DISASSEMBLED VIEWS
Fig. 1: Case and Associated Parts

Courtesy of GENERAL MOTORS CORP.
Callout Component Name

1 Torque Converter Assembly
2 Torque Converter (with Fluid Pump) Housing Assembly - Model Dependent
3 Bolt, M10 x 50 mm
4 Torque Converter Housing Access Hole Cover - Model Dependent
5 A/Trans Fluid Pump Seal
6 Torque Converter Housing Locator Pin
7 A/Trans Case Assembly
8 Transmission Fluid Fill Tube Plug Assembly
9 A/Trans Connector Seal
10 A/Trans Connector (O-ring) Seal
11 A/Trans Electrical Connector Passage Sleeve

12 A/Trans Case Plug
13 Output Shaft Bushing
14 Output Shaft Seal Assembly
15 A/Trans Case Extension - Model Dependent
16 Bolt, M10 x 40 mm - Model Dependent
17 A/Trans Case Extension Stud - Model Dependent
18 A/Trans Fluid Pump Seal Assembly
20 Center Support Fluid Passage Seal Assembly
21 Control (with Body and Valve) Valve Assembly
22 Bolt, M5 x 73 mm
23 Bolt, M6 x 14.5 mm
24 Manual Shaft Detent Assembly
25 A/Trans Fluid Filter Seal Assembly
26 A/Trans Fluid Filter Assembly
27 A/Trans Fluid Pan Gasket
28 A/Trans Fluid Pan Magnet
29 A/Trans Fluid Pan Assembly
30 Bolt, M6 x 20 mm
31 Trans Oil Level Check Plug
32 Torque Converter Housing Access Hole Cover - Model Dependent
Fig. 2: Clutch Assemblies and Associated Parts


51 1-2-3-4 and 3-5 Reverse Clutch Assembly
52 Input Carrier Assembly
53 Input Sun Gear
54 Input Sun Gear Thrust Bearing
55 Input Sun Gear Thrust Washer
56 4-5-6 (w/ Turbine Shaft) Clutch Assembly
57 Turbine Shaft Thrust Bearing Assembly
58 4-5-6 Clutch (w/ Output Carrier Shaft and Dampener) Hub Assembly
59 4-5-6 Clutch Hub Thrust Bearing Assembly
60 Output Carrier Inner Sun Gear Shaft (Front) Bushing
61 1-2-3-4 Clutch (w/ Output Carrier Inner Sun Gear Shaft) Hub Assembly
62 Output Carrier Inner Sun Gear Shaft Bushing
63 1-2-3-4 Clutch Hub Thrust Bearing Assembly

2-6 and 3-5 Reverse Clutch (w/ Output Carrier Outer Sun Gear Shaft) Hub
64
Assembly
65 2-6 and 3-5 Reverse Clutch Hub Thrust Bearing Assembly
66 Center Support Retaining Ring
67 Center (w/ 2-6 Low and Reverse Clutch) Support Assembly
68 Output Carrier Assembly
69 Output Carrier Thrust Bearing Assembly
70 Output Shaft Assembly - Model Dependent
71 Output Shaft Thrust Bearing Assembly
Fig. 3: Torque Converter (w/Fluid Pump) Housing Assembly


200 Torque Converter Fluid Seal Retaining Ring
201 Torque Converter Fluid Seal Assembly
202 Line Pressure Test Hole Plug
203 Torque Converter Housing - Model Dependent

204 A/Trans Vent Pipe - Model Dependent
205 Trans Fluid Cooler Pipe Fitting Seal
206 Torque Converter Bushing
207 A/Trans Fluid Pump Vane Ring
208 A/Trans Fluid Pump Rotor Guide
209 A/Trans Fluid Pump Slide Fluid Seal Ring
210 A/Trans Fluid Pump Slide (O-ring) Seal
211 A/Trans Fluid Pump Slide Outer Spring
212 A/Trans Fluid Pump Slide
213 A/Trans Fluid Pump Slide Seal
214 A/Trans Fluid Pump Slide Seal Support
215 A/Trans Fluid Pump Slide Pivot Pin
216 A/Trans Fluid Pump Vane
217 A/Trans Fluid Pump Rotor
218 Turbine Shaft Front Bushing
219 A/Trans Fluid Pump Cover Assembly
220 Converter Feed Limit Valve
221 Converter Feed Limit Valve Spring
222 Valve Spring Retainer
223 Pressure Relief Ball Valve Spring Pin
224 Pressure Relief Ball Valve Spring
225 Pressure Relief Ball Valve
226 TCC Control Valve Spring
227 TCC Control Valve
228 Turbine Shaft Rear Bushing
229 1-2-3-4 and 3-5 Reverse Clutch Housing Thrust Washer
230 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring
231 Bolt, M6 x 40 mm
232 A/Trans Fluid Pump Locator Pin
233 Pressure Regulator Valve
234 Pressure Regulator Valve Outer Spring
235 Pressure Regulator Valve Inner Spring
236 Isolator Valve
237 Isolator Valve Sleeve
Fig. 4: Control (with Body and Valve) Valve Assembly


303 A/Trans Input and Output Speed Sensor Assembly
304 Control Valve Upper Body Assembly
305 Control Valve Body Spacer (w/ Gasket) Plate Assembly
306 Control Valve Body Ball Check Valve
307 Control Valve Lower Body Assembly
308 A/Trans Manual Shift Shaft Position Switch Assembly
311 Filter Plate Assembly
314 Control Solenoid (w/ Body and TCM) Valve Assembly
315 A/Trans Manual Shaft Position Switch Wiring Harness Clip

316 A/Trans Input and Output Speed Sensor Wiring Harness Clip
Fig. 5: Upper Control Valve Body Assembly


313 Control Valve Body Locator Pin
321 Control Valve Upper Body
323 Retainer
324 Actuator Feed Limit Valve Spring
325 Actuator Feed Limit Valve
326 Clutch Regulator Valve Spring
327 1st/Reverse Band and 4-5-6 Clutch Regulator Valve
328 Clutch Regulator Valve Bore Plug
329 Clutch Boost Valve
330 Clutch Boost Valve Spring
334 2-6 Clutch Regulator Valve
335 2-6 Clutch Regulator Valve Gain Valve
336 3-5 Reverse Clutch Regulator Valve
337 1-2-3-4 Clutch Regulator Valve
338 Shuttle Valve
Fig. 6: Lower Control Valve Body Assembly


323 Retainer
328 Clutch Regulator Valve Bore Plug
338 Shuttle Valve
351 Control Valve Lower Body
352 Clutch Select Solenoid Valve
353 Clutch Select Solenoid Valve Spring
354 Manual Valve
355 TCC Regulator Apply Valve
356 Clutch Piston Dam Feed Regulator Valve
357 Clutch Piston Dam Feed Regulator Valve Spring
Fig. 7: 1-2-3-4 and 3-5 Reverse Clutch Assembly


400 3-5 Reverse Clutch Backing Plate Retaining Ring
401 3-5 Reverse Clutch Backing Plate
402 3-5 Reverse Clutch Plate Assembly
403 3-5 Reverse Clutch Plate
404 3-5 Reverse Clutch (Waved) Plate
405 3-5 Reverse Clutch Apply Ring
407 1-2-3-4 Clutch Backing Plate
408 1-2-3-4 Clutch Plate Assembly
409 1-2-3-4 Clutch Plate
410 1-2-3-4 Clutch (Waved) Plate
411 1-2-3-4 Clutch Piston Dam Retaining Ring
412 1-2-3-4 Clutch Piston Dam Assembly
413 1-2-3-4 Clutch Spring
414 1-2-3-4 Clutch Piston

415 1-2-3-4 Clutch Piston Housing Retaining Ring
416 1-2-3-4 Clutch Piston Seal
417 1-2-3-4 Clutch Piston Housing
418 3-5 Reverse Clutch Piston Dam (O-ring) Seal
419 3-5 Reverse Clutch Piston Inner Seal
420 3-5 Reverse Clutch Spring
421 3-5 Reverse Clutch Piston
422 3-5 Reverse Clutch Piston Outer Seal
423 1-2-3-4 Clutch Piston Inner Seal
424 1-2-3-4 Clutch Piston Housing Seal
426 1-2-3-4 and 3-5 Reverse Clutch Housing Rear Bushing
427 1-2-3-4 and 3-5 Reverse Clutch Housing Assembly
428 1-2-3-4 and 3-5 Reverse Clutch Bearing Assembly
429 1-2-3-4 Clutch Backing Plate Retaining Ring
Fig. 8: 4-5-6 (w/Turbine Shaft) Clutch Assembly


431 4-5-6 Clutch Backing Plate Retaining Ring
432 4-5-6 Clutch Backing Plate
433 4-5-6 Clutch Plate Assembly

434 4-5-6 Clutch Plate
435 4-5-6 Clutch (Waved) Plate
436 4-5-6 Clutch Piston Dam Retaining Ring
437 4-5-6 Clutch Piston Dam Assembly
438 4-5-6 Clutch Spring
439 4-5-6 Clutch Piston Assembly
440 Output Carrier Shaft Housing Bushing
441 4-5-6 (w/Turbine Shaft) Housing Assembly
442 Turbine Shaft Fluid Seal Ring
443 Turbine Shaft (O-ring) Seal
Fig. 9: 2-6 Clutch Assembly


450 2-6 Clutch Backing Plate Retaining Ring
451 2-6 Clutch Backing Plate
452 2-6 Clutch Plate Assembly
453 2-6 Clutch Plate
454 2-6 Clutch (Waved) Plate
455 2-6 Clutch Spring Retaining Ring
456 2-6 Clutch Spring
457 2-6 Clutch Piston Assembly

458 Output Carrier Outer Sun Gear Shaft (Front) Bushing
459 Center Support Assembly
460 Output Carrier Outer Sun Gear Shaft Rear Bushing
Fig. 10: Low and Reverse Clutch Assembly


459 Center Support Assembly
461 Low and Reverse Clutch Backing Plate Retaining Ring
462 Low and Reverse Clutch Backing Plate
463 Low and Reverse Clutch Plate Assembly
464 Low and Reverse Clutch Plate
465 Low and Reverse Clutch (Waved) Plate
466 Low and Reverse Clutch Spring Retaining Ring
467 Low Clutch Sprag Assembly
468 Low Clutch Sprag Seal

469 Low and Reverse Clutch Spring
470 Low and Reverse Clutch Piston Assembly
Fig. 11: 4-5-6 Clutch Hub Assembly


475 4-5-6 Clutch (w/ Output Carrier Shaft) Hub Assembly
476 4-5-6 Clutch Dampener
477 4-5-6 Clutch Dampener Apply Plate
478 4-5-6 Clutch Dampener Retaining Ring
Fig. 12: Output Carrier Assembly


485 Center Support Roller Bearing Assembly
486 Output Carrier Front Sun Gear Thrust Bearing Assembly
487 Output Carrier Front Sun Gear
488 Output Carrier Front Sun Gear Rear Thrust Bearing Assembly
489 Output Carrier Rear Sun Gear
490 Output Carrier
491 Output Carrier Rear Sun Gear Thrust Bearing Assembly - Captured
Fig. 13: Output Shaft Assembly


494 Output Carrier Internal Gear Retaining Ring
495 Output Carrier Internal Front Gear
496 Output Carrier Internal Gear Spacer
497 Output Carrier Internal Rear Gear
498 Output Carrier Bushing
499 Output Shaft Assembly - Model Dependent
Fig. 14: Park System Components


12 A/Trans Case Plug
500 Park Pawl Shaft
501 Park Pawl Spring
502 Park Pawl
503 Park Pawl Actuator Assembly
504 Manual Shaft Detent Lever Hub Pin
505 Manual Shaft Detent Lever Assembly
506 Manual Shift Shaft Pin
507 Manual Shift Shaft Seal
508 Manual Shift Shaft
509 Park Pawl Actuator Guide
510 Park Pawl Actuator Guide (O-ring) Seal
511 Park Pawl Actuator Guide Pin
AUTOMATIC TRANSMISSION ELECTRONIC COMPONENT VIEWS
Fig. 15: Electronic Components


1 Control Solenoid (with Body and TCM) Valve Assembly
3 A/Trans Manual Shift Shaft Position Switch Assembly
COMPONENT LOCATION
Fig. 16: Component Locations


2 Torque Converter (with Fluid Pump) Housing Assembly
21 Control (with Body and Valve) Valve Assembly
53 Input Sun Gear
56 4-5-6 (w/Turbine Shaft) Clutch Assembly
58 4-5-6 Clutch (w/Output Carrier Shaft and Dampener) Hub Assembly
61 1-2-3-4 Clutch (w/Output Carrier Inner Sun Gear Shaft) Hub Assembly
2-6 and 3-5 Reverse Clutch (w/Output Carrier Outer Sun Gear Shaft) Hub
64
Assembly
67 Center (w/2-6 Low and Reverse Clutch) Support Assembly
70 Output Shaft Assembly
402 3-5 Reverse Clutch Plate Assembly
408 1-2-3-4 Clutch Plate Assembly
452 2-6 Clutch Plate Assembly
463 Low and Reverse Clutch Plate Assembly
487 Output Carrier Front Sun Gear

489 Output Carrier Rear Sun Gear
502 Park Pawl
508 Manual Shift Shaft
BUSHING, BEARING, AND WASHER LOCATIONS (6L80)
Fig. 17: Bushing, Bearing and Washer Locations



60 Output Carrier Inner Sun Gear Shaft (Front) Bushing
62 Output Carrier Inner Sun Gear Shaft Bushing
65 2-6 and 3-5 Reverse Clutch Hub Thrust Bearing Assembly
218 Turbine Shaft Front Bushing
228 Turbine Shaft Rear Bushing
229 1-2-3-4 and 3-5 Reverse Clutch Housing Thrust Washer
426 1-2-3-4 and 3-5 Reverse Clutch Housing Rear Bushing
428 1-2-3-4 and 3-5 Reverse Clutch Bearing Assembly
440 Output Carrier Shaft Housing Bushing
458 Output Carrier Outer Sun Gear Shaft (Front) Bushing
460 Output Carrier Outer Sun Gear Shaft Rear Bushing
485 Center Support Roller Bearing Assembly
486 Output Carrier Front Sun Gear Thrust Bearing Assembly
488 Output Carrier Front Sun Gear Rear Thrust Bearing Assembly
491 Output Carrier Rear Sun Gear Thrust Bearing - Captured
498 Output Carrier Bushing
SEAL LOCATIONS (6L80)
Fig. 18: Seal Locations


5 A/Trans Fluid Pump Seal
9 A/Trans Connector Seal
10 A/Trans Connector (O-ring) Seal
14 Output Shaft Seal Assembly
20 Center Support Fluid Passage Seal Assembly
25 A/Trans Fluid Filter Seal Assembly
27 A/Trans Fluid Pan Gasket
201 Torque Converter Fluid Seal Assembly
209 A/Trans Fluid Pump Slide Fluid Seal Ring
210 A/Trans Fluid Pump Slide (O-ring) Seal
213 A/Trans Fluid Pump Slide Seal
230 1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Ring

412 1-2-3-4 Clutch Piston Dam Assembly
418 3-5 Reverse Clutch Piston Dam (O-ring) Seal
423 1-2-3-4 Clutch Piston Inner Seal
437 4-5-6 Clutch Piston Dam Assembly
442 Turbine Shaft Fluid Seal Ring
457 2-6 Clutch Piston Assembly
468 Low Clutch Sprag Seal
470 Low and Reverse Clutch Piston Assembly
507 Manual Shift Shaft Seal
510 Park Pawl Actuator Guide (O-ring) Seal
BALL CHECK VALVE LOCATIONS
Fig. 19: Ball Check Valve Locations

Ball Check Valve Locations

I.D. Input Oil Input Oil Output Oil
1 Drive 1-6 DRV B CB26/C1234 FD
2 Sol 1 Reverse (Park) CSV2 Enable
3 Sol 2 C456 CSV3 Enable
4 PS4 C456 CSV2 Latch
5 Drive 1-6 C35R Rev FD C35R Supply
6 CB26/C1234 FD - C1234 FD
7 C35R Supply - C35R FD
REPAIR INSTRUCTIONS
TORQUE CONVERTER REMOVAL AND HOLDING FIXTURE INSTALLATION
Fig. 20: Removing Torque Converter and Installing Holding Fixture

Torque Converter Removal and Holding Fixture Installation

Transmission Case Assembly

Tip:
1. Rotate the transmission so that the converter housing
is up and secure with locking pin.

2. Allow any remaining transmission fluid to drain from
the case extension.
Special Tools
2
DT 47605 Holding Fixture Adapter. See Special
Tools.
J 3289-20 Holding Fixture Base Assembly
J 8763-B Holding Fixture
CASE EXTENSION ASSEMBLY REMOVAL
Fig. 21: Removing Case Extension Assembly

Case Extension Assembly Removal

1 Bolt M10 x 40 (Quantity: 6)
2 Case Extension Studs (Quantity: 2)
3 Case Extension
FLUID PAN, FLUID FILTER AND ELECTRICAL CONNECTOR PASSAGE SLEEVE REMOVAL
Fig. 22: Removing Fluid Pan, Fluid Filter, and Electrical Connector Passage Sleeve
Fluid Pan, Fluid Filter and Electrical Connector Passage Sleeve Removal
2 Fluid Pan Assembly
Fluid Pan Gasket
Tip: The fluid pan gasket is reusable. Inspect the gasket to
3
determine if it may be reused. If the gasket is stuck to the case or
pan, it should be replaced.
Fluid Filter Assembly
4 NOTE:
Pull the fluid filter assembly straight out to avoid damage. Do
not bend or twist the filter neck.
Fluid Filter Seal Assembly
NOTE:
Do not damage the case sealing surface when removing the
filter seal assembly.
5
Tip: Use a screwdriver or snap ring pliers.

Electrical Connector Slide Lock
6 NOTE:
Pull up on the electrical connector slide lock to avoid damage to
the connector.
Electrical Connector Passage Sleeve
Special Tools
7
DT 47715 Electrical Connector Passage Sleeve
Remover/Installer. See Special Tools.
J 42183 Driver Handle. See Special Tools.
CONTROL VALVE BODY ASSEMBLY REMOVAL
Fig. 23: Removing Control Valve Body Assembly

Control Valve Body Assembly Removal

Bolt M5 x 73 (Quantity: 6)
1 Tip: Do not remove all the bolts in the control valve
body assembly. Remove only the bolts indicated.
Control Valve Body Assembly
NOTE:
2 Use care when handling the control valve body
assembly. If dropped, damage to the control
solenoid valve body assembly internal
components, including the transmission control
module (TCM), may result.
Fluid Pump Seal Assembly
3
NOTE:
Refer to Seal Reuse Notice .

Fluid Pump Seal Assembly
4 NOTE:
Center Support Fluid Passage Seal Assembly
5 NOTE:
TORQUE CONVERTER HOUSING WITH FLUID PUMP REMOVAL
Fig. 24: Removing Torque Converter Housing with Fluid Pump

Torque Converter Housing with Fluid Pump Removal

NOTE:
The valve body assembly must be removed prior to removing the torque converter (with fluid pump)
housing assembly. Failure to ensure this will cause severe damage to both fluid pump seal
assemblies. Also, the load of the valve body pushing on the seals, which in turn push on the pump,
may prevent proper pump installation into the case.
Tip: Refer to Control Valve Body Assembly Removal.

Torque Converter (With Fluid Pump) Housing
3
Assembly
4 Fluid Pump Seal
1-2-3-4 AND 3-5 REVERSE CLUTCH ASSEMBLY AND 4-5-6 CLUTCH ASSEMBLY REMOVAL
Fig. 25: Removing 1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly
1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly Removal
1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-
1
5-6 (With Turbine Shaft) Clutch Assembly
4-5-6 Clutch (With Output Carrier Shaft and
3
Dampener) Hub Assembly

1-2-3-4 Clutch (With Output Carrier Inner Sun
5
Gear Shaft) Hub Assembly
2-6 and 3-5 Reverse Clutch (With Output Carrier
7
Outer Sun Gear Shaft) Hub Assembly
2-6 and 3-5 Reverse Clutch Hub Thrust Bearing
8
Assembly
11 Input Sun Gear
14 4-5-6 (With Turbine Shaft) Clutch Assembly
CENTER SUPPORT, OUTPUT CARRIER AND OUTPUT SHAFT REMOVAL
Fig. 26: Removing Center Support, Output Carrier and Output Shaft
Center Support, Output Carrier and Output Shaft Removal

Center Support Retaining Ring
CAUTION:
Use care when removing or installing the retaining
ring. Ensure the J 45126 and DT 47773 are
installed properly onto the retaining ring or bodily
injury may occur.
Tip: To release tension on the retaining ring, place

1 the retaining ring flat on the floor and step on it, then
remove the tool.
Special Tools
DT 47773 Snap Ring Pliers Adapter Set. See

Special Tools.
J 45126 Snap Ring Pliers
Center (with 2-6 Low and Reverse Clutch) Support
2
Assembly
Output Carrier Assembly and Output Shaft Assembly
NOTE:
Ensure the DT 47786 is completely threaded into
the output shaft assembly. Due to the weight of
the assembly, incomplete threading may cause the
3 assembly to break free from the DT 47786, causing
component damage.
Special Tool:
DT 47786 Output Carrier/Shaft Lifting Tool. See
Special Tools.
MANUAL SHIFT SHAFT AND PARKING SYSTEM COMPONENTS OVERHAUL
Fig. 27: Overhauling Manual Shift Shaft and Parking System Components
Manual Shift Shaft and Parking System Components Overhaul

Manual Shaft Detent Lever Hub Pin
1 NOTE:
Refer to Pin Reuse Notice .
Manual Shift Shaft Pin
2 NOTE:
Manual Shift Shaft
NOTE:
Ensure the manual shift shaft seal is replaced
before installing the shaft. Installing the seal after
the shaft may cause damage to the seal, resulting

in fluid leaks and transmission damage.
3
Tip: Refer to Manual Shift Shaft Seal
Replacement.
Park Pawl Actuator Guide Pin
NOTE:
6
Tip: Use a large pair of side cutters to "walk" the pin

out.
7 Park Pawl Actuator Guide
Park Pawl Actuator Guide (O-ring) Seals
8 NOTE:
Park Pawl
9 Tip: Inspect for damage only. Do not remove. The
park pawl is not a serviceable component.
Park Pawl Spring
park pawl spring is not a serviceable component.
MANUAL SHIFT SHAFT SEAL REPLACEMENT
Fig. 28: Replacing Manual Shift Shaft Seal

Manual Shift Shaft Seal Replacement

Callout Component Procedure
Manual Shift Shaft Seal
NOTE:
Do not damage the case bore during removal of the
manual shift shaft seal.
NOTE:
When installing the seal, ensure the seal lip is firmly
seated against the case bore surface. Do not allow
1 the seal lip to be crushed, or a leak may result.
NOTE:
Special Tools
DT 47770 Seal Installer. See Special Tools.

J 45201 Cooler Line Seal Remover. See Special
Tools.
OUTPUT SHAFT SEAL REPLACEMENT
Fig. 29: Replacing Output Shaft Seal

Output Shaft Seal Replacement

Output Shaft Seal
NOTE:
Use care not to damage the output shaft bushing
with the J 45000.
1 NOTE:
Special Tools
J 38693 Seal Installer. See Special Tools.

J 45000 Seal Remover
CASE INSPECTION
Fig. 30: Inspecting Case

Case Inspection
NOTE:
After cleaning the transmission components, allow to air dry. Do not use cloth or paper towels in
order to dry any transmission components. Lint from the towels can cause component failure.
NOTE:
Do not reuse cleaning solvents. Previously used solvents may deposit sediment which may damage
the component.
Preliminary Procedures
1. Thoroughly clean the transmission case assembly, including case threads, with clean solvent.
2. Clean gasket sealing surfaces. Remove all residual gasket material.
3. Inspect all threaded holes. If necessary, repair any thread damage.
1 Front Case Sealing Surface
Manual Shift Shaft Seal
2 Tip: Refer to Manual Shift Shaft Seal
Replacement.
3 Center Support Fluid Passage Seal Bores
4 Fluid Pan Sealing Surface
5 Case Plugs

7 Rear Case Sealing Surface
8 Fill Tube Bore
9 Electrical Connector Passage Sleeve Bore
OUTPUT SHAFT DISASSEMBLE
Fig. 31: Disassembling Output Shaft

Output Shaft Disassemble

Tip: Inspect each component and replace as necessary.
5 Output Carrier Internal Gear Spacer
OUTPUT SHAFT ASSEMBLE
Fig. 32: Assembling Output Shaft

Output Shaft Assemble

Output Carrier Internal Rear Gear
NOTE:
1
Install the gear chamfer side down. Failure to
install the gear chamfer side down may result in
transmission damage.
2 Output Gear Internal Gear Spacer
Output Carrier Internal Gear Retaining Ring
Tip: Do not install the output carrier internal front
3 gear and retaining ring yet. These components will be
installed during assembly of the output carrier to the
output shaft.
OUTPUT CARRIER ASSEMBLY OVERHAUL
Fig. 33: Overhauling Output Carrier Assembly

Output Carrier Assembly Overhaul

Output Carrier Front Sun Gear Thrust Bearing
1
Assembly
Center Support Roller Bearing
NOTE:
Do not reuse the center support roller bearing. Install
a NEW center support roller bearing. Reusing an old
bearing may result in damage to the output carrier.
2 Tip: The thick side of the bearing shell faces up.
Special Tools
DT 47857 Bearing Installer. See Special Tools.

J 6125-B Slide Hammer. See Special Tools.
J 8092 Driver Handle
J 23129 Universal Seal Remover
Output Carrier Front Sun Gear
NOTE:
3 Install the gear chamfer side up. Failure to install the
gear chamfer side up may result in transmission
damage.
Output Carrier Front Sun Gear Rear Thrust Bearing
4
Assembly
Output Carrier Rear Sun Gear
NOTE:
5
Install the gear chamfer side up. Failure to install the
gear chamfer side up may result in transmission
damage.
Output Carrier Rear Sun Gear Bearing Assembly
bearing assembly is not a serviceable component.
OUTPUT CARRIER TO OUTPUT SHAFT ASSEMBLE
Fig. 34: Assembling Output Carrier to Output Shaft

Output Carrier to Output Shaft Assemble

Output Carrier Internal Front Gear
NOTE:
Install the gear flat side down. Failure to install the
2 gear flat side down may result in transmission
damage.
Output Carrier Internal Gear Retaining Ring
4 Tip: Grasp the output shaft and carrier with both
hands to turn over.
2-6 CLUTCH OVERHAUL (6L80)
2-6 Clutch Plates Removal
Fig. 35: Overhauling 2-6 Clutch (6L80)

2-6 Clutch Plates Removal

3 2-6 Clutch Plate Assembly (Quantity: 5)
4 2-6 Clutch Plate (Quantity: 5)
2-6 Clutch Piston Replacement
Fig. 36: Replacing 2-6 Clutch Piston

2-6 Clutch Piston Replacement

2-6 Clutch Spring Retaining Ring
Tip: Ensure the DT 47761 is centered over the
clutch spring. See Special Tools.
1
Special Tool:
DT 47761 Clutch Spring Compressor. See Special
Tools.
2-6 Clutch Spring
NOTE:
2 Ensure the spring tabs are facing down during
installation and that the tabs fit between the
teeth on the piston. Failure to do so may cause
damage to the clutch assembly.
2-6 Clutch Piston Assembly
3 Tip: It may be necessary to apply air to the apply
passage in order to unseat the piston.
2-6 Clutch Plates Installation
Fig. 37: Installing 2-6 Clutch Plates

2-6 Clutch Plates Installation

2-6 Clutch Plates (Quantity: 5)
2 Tip: Alternate between steel and fiber clutch
plates.
2-6 Clutch Plate Assembly (Quantity: 5)
3 Tip: Alternate between steel and fiber clutch
plates.
2-6 Clutch Apply Passage
6 Tip: Apply air to verify proper installation of all
2-6 clutch components.
LOW AND REVERSE CLUTCH OVERHAUL
Low and Reverse Clutch Plate Removal
Fig. 38: Removing Low And Reverse Clutch Plate

Low and Reverse Clutch Plate Removal

Low and Reverse Clutch Backing Plate Retaining
1
Ring
Low and Reverse Clutch Plate Assembly
3
(Quantity: 5)
4 Low and Reverse Clutch Plate (Quantity: 5)
Low and Reverse Clutch Piston Removal
Fig. 39: Removing Low And Reverse Clutch Piston

Low and Reverse Clutch Piston Removal

Low and Reverse Clutch Spring Retaining Ring
NOTE:
Ensure the DT 47779 contacts the sprag
assembly and not the sprag retaining ring.
1 Damage to the sprag may result.
Special Tool:
Tools.
3 Low and Reverse Clutch Spring
Low and Reverse Clutch Piston Assembly
4 Tip: It may be necessary to apply air to the apply
passage in order to unseat the piston.
Low Clutch Sprag Seal
5 NOTE:
Low and Reverse Clutch Piston Installation
Fig. 40: Installing Low And Reverse Clutch Piston

Low and Reverse Clutch Piston Installation

Low and Reverse Clutch Piston Assembly
Tip: Lubricate the inner and outer sealing surfaces of the
1
piston assembly with automatic transmission fluid (ATF) in
order to ease installation into the center support assembly.
Low Clutch Sprag Seal
NOTE:
2
Tip: Apply ATF to the DT 47780 to ease seal installation.
See Special Tools.
Special Tool:
DT 47780 Low Clutch Sprag Seal Cone. See Special Tools.
Low and Reverse Clutch Spring
3 NOTE:
Ensure the spring tabs are facing up during installation.
Failure to do so may cause damage to the clutch
assembly.
Low Clutch Sprag Assembly
Tip:
Verify that the low clutch sprag is operating correctly.

4 Refer to the illustration for proper freewheel direction.
Ensure the missing splines on the sprag assembly are
aligned with the missing splines on the center support
hub.
Low and Reverse Clutch Spring Retaining Ring
NOTE:
Ensure the DT 47779 contacts the sprag assembly and
not the sprag retaining ring. Damage to the sprag may
result.
NOTE:
The retaining ring gap must be aligned with the 3 missing
splines on the center support hub. Failure to do so may
5 cause damage to the clutch assembly.
Special Tools
DT 47778-1 Low Clutch Sprag Retaining Ring Cone.

See Special Tools.
DT 47778-2 Low Clutch Sprag Retaining Ring
Pusher. See Special Tools.
Tools.
Low and Reverse Clutch Plate Installation
Fig. 41: Installing Low And Reverse Clutch Plate

Low and Reverse Clutch Plate Installation

2 Low and Reverse Clutch Plate (Quantity: 5)
Low and Reverse Clutch Plate Assembly
3
(Quantity: 5)
Low and Reverse Clutch Backing Plate Retaining
Ring
5
Tip: Apply air to verify proper installation of all
low and reverse clutch components.
4-5-6 CLUTCH DAMPENER OVERHAUL
Fig. 42: Overhauling 4-5-6 Clutch Dampener

4-5-6 Clutch Dampener Overhaul

4-5-6 Clutch Dampener Retaining Ring
NOTE:
1 Ensure the retaining ring is fully seated when installed.
Using a screwdriver, fully seat the retaining ring into the
groove by pushing on the inside diameter around the
whole circumference. If the retaining ring is not fully
seated, transmission damage will result.
2 4-5-6 Clutch Dampener Apply Plate
4-5-6 Clutch Dampener
Tip: Dry and inspect the clutch dampener for the following
conditions:
Pitting
3 Flaking
Delamination
Wear
Glazing
Cracking
4-5-6 CLUTCH OVERHAUL
4-5-6 Clutch Plates Removal
Fig. 43: Removing 4-5-6 Clutch Plates

4-5-6 Clutch Plates Removal

1 4-5-6 Clutch Backing Plate Retaining Ring
3 4-5-6 Clutch Plate Assembly (Quantity: 6)
4 4-5-6 Clutch Plate (Quantity: 6)
4-5-6 Clutch Piston Removal
Fig. 44: Removing 4-5-6 Clutch Piston

4-5-6 Clutch Piston Removal

4-5-6 Clutch Piston Dam Retaining Ring
NOTE:
Use care when compressing the 4-5-6 clutch piston
assembly, spring and dam assembly. Compressing
the dam assembly too much may damage it.
1
NOTE:
Refer to Retaining Ring Reuse Notice .
Special Tool:
J 43074 Clutch Spring Compressor. See Special
Tools.
4-5-6 Clutch Piston Dam Assembly
2 Tip: It may be necessary to apply air pressure to
remove the dam and piston.
3 4-5-6 Clutch Spring

Tip: It may be necessary to apply air pressure to
remove the piston.
Turbine Shaft Fluid Seal Ring Replacement
Fig. 45: Replacing Turbine Shaft Fluid Seal Ring

Turbine Shaft Fluid Seal Ring Replacement

Inspect the turbine shaft fluid passages and splines.

Clean any plugged passages.
Turbine Shaft Fluid Seal Ring (Quantity: 3)
NOTE:
Do not use old seal rings. Install NEW seal rings.
Reusing old seal rings may cause internal
1 transmission leaks and transmission damage.
NOTE:
Size the fluid seal rings for at least 5 minutes after
installation to obtain proper seal ring size. Failure to
do so may cause internal transmission leaks and
Tip: Adjust the turn screw on the DT 47768-1 and

install the bottom seal ring first. See Special Tools.
Special Tools
DT 47768-1 Seal Protector. See Special Tools.

DT 47768-2 Seal Pusher. See Special Tools.
DT 47768-3 Seal Sizer. See Special Tools.
4-5-6 Clutch Piston Installation
Fig. 46: Installing 4-5-6 Clutch Piston

4-5-6 Clutch Piston Installation

4-5-6 Clutch Spring
NOTE:
2
Ensure the spring tabs are facing up during
installation. Failure to do so may cause damage to
the clutch assembly.
4-5-6 Clutch Piston Dam Assembly
Tip: Lubricate the inner and outer sealing surfaces of

3 the dam assembly with automatic transmission fluid
(ATF) in order to ease installation into the piston.
4-5-6 Clutch Piston Dam Retaining Ring
NOTE:
Use care when compressing the 4-5-6 clutch piston
assembly, spring and dam assembly. Compressing
the dam assembly too much may damage it.
NOTE:
4 Refer to Retaining Ring Reuse Notice .
Tip: Apply air to verify proper installation of all 4-5-6

clutch components. Piston should apply and release
smoothly.
Special Tool:
J 43074 Clutch Spring Compressor. See Special
Tools.
4-5-6 Clutch Plates Installation
Fig. 47: Installing 4-5-6 Clutch Plates

4-5-6 Clutch Plates Installation

2 4-5-6 Clutch Plate (Quantity: 6)
3 4-5-6 Clutch Plate Assembly (Quantity: 6)
4-5-6 Clutch Backing Plate Retaining Ring
Tip: After the retaining ring is installed, determine
5 clutch piston travel in order to verify if the correct
selective retaining ring is being used. Refer to 4-5-6
Clutch Backing Plate Retaining Ring Measurement.
4-5-6 CLUTCH BACKING PLATE RETAINING RING MEASUREMENT
Fig. 48: Measuring 4-5-6 Clutch Backing Plate Retaining Ring

4-5-6 Clutch Backing Plate Retaining Ring Measurement

1. Install the clutch assembly into a hole in the workbench

2. Zero out the dial indicator on the DT 47868-1 . See Special Tools.
Special Tools
DT 47868-1 Pack Travel Weight. See Special Tools.

J 8001 Dial Indicator Set
J 26900-13 Magnetic Base. See Special Tools.
4-5-6 Clutch Apply Passage
Tip: While using one finger to block the top passage
hole on the turbine shaft, apply compressed air to the
1 opposite top passage hole, and observe the dial
indicator measurement. Refer to Clutch Backing
Plate Retaining Ring Specifications to determine the
correct retainer.
1-2-3-4 AND 3-5 REVERSE CLUTCH OVERHAUL
1-2-3-4 and 3-5 Reverse Clutch Plates Removal
Fig. 49: Removing 1-2-3-4 and 3-5 Reverse Clutch Plates

1-2-3-4 and 3-5 Reverse Clutch Plates Removal

1 3-5 Reverse Clutch Backing Plate Retaining Ring
3 3-5 Reverse Clutch Plate Assembly (Quantity: 4)
4 3-5 Reverse Clutch Plate (Quantity: 4)

6 3-5 Reverse Clutch Apply Ring
7 1-2-3-4 Clutch Backing Plate Retaining Ring
8 1-2-3-4 Clutch Backing Plate
9 1-2-3-4 Clutch Plate Assembly (Quantity: 5)
10 1-2-3-4 Clutch Plate (Quantity: 5)
11 1-2-3-4 Clutch (Waved) Plate
1-2-3-4 Clutch Piston Removal
Fig. 50: Removing 1-2-3-4 Clutch Piston

1-2-3-4 Clutch Piston Removal

1-2-3-4 Clutch Piston Dam Retaining Ring.
NOTE:
Use care when compressing the 1-2-3-4 clutch
1
spring and dam assembly. Compressing the dam
assembly too much may damage it.
NOTE:
Special Tool:
J 38734 Intermediate Spring Compressor Adapter
2 1-2-3-4 Clutch Piston Dam Assembly.
3 1-2-3-4 Clutch Spring
1-2-3-4 Clutch Piston
Tip: It may be necessary to apply air to the apply
passage in order to remove the piston. Install the 1-2-
3-4 clutch housing onto the torque converter (with
4 fluid pump) housing assembly in order to apply air.
Tip: After air is applied, it may be necessary to turn
the housing assembly upside down and carefully tap
the housing against a flat surface in order to release the
piston.
3-5 Reverse Clutch Piston Removal
Fig. 51: Removing 3-5 Reverse Clutch Piston

3-5 Reverse Clutch Piston Removal

1-2-3-4 Clutch Piston Housing Retaining Ring
NOTE:
1
Special Tool:
DT 47867 Adjustable Clutch Spring Compressor.
See Special Tools.
1. Install the 1-2-3-4 and 3-5 reverse clutch housing assembly onto the torque converter (with fluid
pump) housing assembly.
2. Apply hand pressure on the 1-2-3-4 clutch piston housing while applying compressed air to the
apply passage in order to unseat the 3-5 reverse clutch piston.
3 3-5 Reverse Clutch Spring
3-5 Reverse Clutch Piston
Tip: It may be necessary to turn the housing
4 assembly upside down and carefully tap the
housing against a flat surface in order to release
the piston.
1-2-3-4 and 3-5 Reverse Clutch Piston Seals Replacement
Fig. 52: Replacing 1-2-3-4 and 3-5 Reverse Clutch Piston Seals
1-2-3-4 and 3-5 Reverse Clutch Piston Seals Replacement

NOTE:
Tip: Lubricate all seals with automatic transmission fluid (ATF) prior to installation.
2 3-5 Reverse Clutch Piston Dam (O-Ring) Seal
1-2-3-4 Clutch Piston Inner Seal
NOTE:
Do not install a NEW 1-2-3-4 clutch piston inner
7 seal yet. A special tool used to install the 1-2-3-4
clutch piston housing retaining ring may
damage the seal if the seal is installed prior to
installing the retaining ring. Refer to 3-5 Reverse
Clutch Piston Installation.
3-5 Reverse Clutch Piston Installation
Fig. 53: Installing 3-5 Reverse Clutch Piston

3-5 Reverse Clutch Piston Installation

3-5 Reverse Clutch Spring
NOTE:
2
Ensure the clutch spring is centered on the piston
with the tabs facing up. Failure to do so may cause
1-2-3-4 Clutch Piston Housing Retaining Ring
NOTE:
Before using the DT 47782-2, push the retaining ring
over the DT 47782-1 by hand so that the ring is
positioned below the tapered area of the DT 47782-1.
If the ring is positioned above the tapered area when
it is being installed, the ring will become lodged
between both tools and damage to the tools,
retaining ring, and piston housing will result.
NOTE:
NOTE:
Push the retaining ring down over the cone until the
ring seats firmly in the retaining ring groove. The
retaining ring will make a distinctive click sound
when it seats. Failure to properly seat the retaining
ring may cause damage to the 3-5 reverse clutch
assembly.
4
Special Tools
DT 47782-1 Retaining Ring Cone. See Special

Tools.
DT 47782-2 Retaining Ring Installer. See Special
Tools.
1-2-3-4 Clutch Piston Inner Seal
NOTE:
5
Install a NEW seal and orientate as shown. Failure to
do so may cause internal transmission leaks and
damage to the transmission.
1-2-3-4 Clutch Piston Installation
Fig. 54: Installing 1-2-3-4 Clutch Piston

1-2-3-4 Clutch Piston Installation

1 1-2-3-4 Clutch Piston
1-2-3-4 Clutch Spring
NOTE:
2
Ensure the clutch spring is centered on the piston
with the tabs facing up. Failure to do so may cause
1-2-3-4 Clutch Piston Dam Assembly
Tip: Lubricate the inner and outer surfaces of the dam
3
assembly with ATF in order to ease installation into
the piston. Install the tabs facing up.
1-2-3-4 Clutch Piston Dam Retaining Ring
NOTE:
Use care when compressing the 1-2-3-4 clutch
spring and dam assembly. Compressing the dam
assembly too much may damage it.
4
NOTE:
Special Tool:
J 38734 Intermediate Spring Compressor Adapter
1-2-3-4 Clutch Plate Installation
Fig. 55: Installing 1-2-3-4 Clutch Plate

1-2-3-4 Clutch Plate Installation

1-2-3-4 Clutch (Waved) Plate
NOTE:
1 Ensure an opening between the external splines of
the waved plate is oriented with the missing snap
ring groove punch in the housing. Failure to do so
may cause damage to the clutch assembly.
1-2-3-4 Clutch Plate (Quantity: 5)
NOTE:
Ensure all clutch plates are centered in the housing.
When installing the first steel clutch plate, ensure an
2 opening between the external splines is oriented
with the missing snap ring groove punch in the
housing. Align the external splines of each
remaining steel clutch plate with the first steel
clutch plate. Failure to do so may cause damage to
the clutch assembly.
3 1-2-3-4 Clutch Plate Assembly (Quantity: 5)
1-2-3-4 Clutch Backing Plate
NOTE:
Align the external splines of the backing plate with
4 the external splines of the steel clutch plates.
Failure to do so may cause damage to the clutch
assembly.
1-2-3-4 Clutch Backing Plate Retaining Ring
NOTE:
Align the retaining ring gap with the missing snap
5

clutch piston travel in order to verify if the correct
selective retaining ring is being used. Refer to 1-2-3-4
Clutch Backing Plate Retaining Ring Measurement.
3-5 and Reverse Clutch Plate Installation
Fig. 56: Installing 3-5 and Reverse Clutch Plate

3-5 and Reverse Clutch Plate Installation

3-5 Reverse Clutch Apply Ring
NOTE:
Ensure apply ring legs are positioned into the 3-5
1 reverse clutch piston. Failure to do so may cause
damage to the 3-5 reverse clutch assembly.

3 3-5 Reverse Clutch Plate (Quantity: 4)
4 3-5 Reverse Clutch Plate Assembly (Quantity: 4)
3-5 Reverse Clutch Backing Plate Retaining Ring
NOTE:
Align the retaining ring gap with the missing snap
6

clutch piston travel in order to verify if the correct
selective retaining ring is being used. Refer to 3-5
Reverse Clutch Backing Plate Retaining Ring
Measurement.
1-2-3-4 and 3-5 Reverse Clutch Bearing Assembly Replacement
Fig. 57: Replacing 1-2-3-4 and 3-5 Reverse Clutch Bearing Assembly
1-2-3-4 and 3-5 Reverse Clutch Bearing Assembly Replacement

3-5 Reverse Clutch Bearing
NOTE:
Install the NEW bearing assembly with the seal side
up. Improper installation of the bearing may cause
damage to the transmission.
NOTE:
Do not reuse the bearing. Install a NEW bearing.
Reusing an old bearing may cause damage to the
transmission.
1
Specification: Install the bearing flush to 0.3 mm below
the thrust surface.
Special Tools
DT 47865 Bearing Remover. See Special Tools.

DT 47866 Bearing Installer. See Special Tools.
J 8092 Driver Handle
J 45124 Removal Bridge
1-2-3-4 CLUTCH BACKING PLATE RETAINING RING MEASUREMENT
Fig. 58: Measuring 1-2-3-4 Clutch Backing Plate Retaining Ring

1-2-3-4 Clutch Backing Plate Retaining Ring Measurement

1. Install the 1-2-3-4 and 3-5 reverse clutch housing with the 1-2-3-4 clutch plates installed, onto the
torque converter housing.
2. Install the DT 47868-2 onto the torque converter housing. See Special Tools.
3. Install DT 47868-1 onto the 1-2-3-4 clutch backing plate. See Special Tools.
4. Install the J 26900-13 onto DT 47868-2 . See Special Tools.
5. Attach the J 8001 to the J 26900-13 and zero out the dial indicator on the DT 47868-1 . See
Special Tools.
Special Tools
DT 47868-1 Clutch Pack Travel Weight. See Special Tools.

DT 47868-2 Magnetic Base Adapter. See Special Tools.
1-2-3-4 Clutch Apply Passage
Tip: Apply compressed air to the apply passage hole,
at least 3 times and observe the dial indicator
1
measurement each time. This action "fluffs" the clutch
plates to ensure an accurate measurement. Refer to
Clutch Backing Plate Retaining Ring Specifications.
3-5 REVERSE CLUTCH BACKING PLATE RETAINING RING MEASUREMENT
Fig. 59: Measuring 3-5 Reverse Clutch Backing Plate Retaining Ring
3-5 Reverse Clutch Backing Plate Retaining Ring Measurement

1. Install the 1-2-3-4 and 3-5 reverse clutch housing with the 1-2-3-4 and 3-5 reverse clutch plates
installed, onto the torque converter housing.
2. Install the DT 47868-2 onto the torque converter housing. See Special Tools.
3. Install DT 47868-1 onto the 3-5 reverse clutch backing plate. See Special Tools.
4. Install the J 26900-13 onto DT 47868-2 . See Special Tools.
5. Attach the J 8001 to the J 26900-13 and zero out the dial indicator on the DT 47868-1 . See
Special Tools.
Special Tools
DT 47868-1 Clutch Pack Travel Weight. See Special Tools.

DT 47868-2 Magnetic Base Adapter. See Special Tools.
3-5 Reverse Clutch Apply Passage
Tip: Apply compressed air to the apply passage hole,
1
and observe the dial indicator measurement. Refer to
Clutch Backing Plate Retaining Ring Specifications.
TORQUE CONVERTER HOUSING WITH FLUID PUMP DISASSEMBLE
Fig. 60: Disassembling Torque Converter Housing with Fluid Pump

Torque Converter Housing with Fluid Pump Disassemble

NOTE:
Do not loosen or remove the 6 bolts securing the clutch support to the pump cover assembly. These
bolts have been installed and torqued only after specific clutch support rotational requirements have
been met. If the clutch support is not installed properly, damage to the transmission will occur.
1-2-3-4 and 3-5 Reverse Clutch Housing Thrust
1
Washer
3 Fluid Pump Cover Assembly
4 Fluid Pump Vane Ring
5 Fluid Pump Rotor
6 Fluid Pump Vanes (Quantity: 13)
7 Fluid Pump Rotor Guide
9 Fluid Pump Slide Outer Spring
10 Fluid Pump Slide
11 Fluid Pump Slide (O-Ring) Seal
12 Fluid Pump Slide Fluid Seal Ring
13 Fluid Pump Slide Seal
14 Fluid Pump Slide Seal Support
15 Fluid Pump Slide Pivot Pin
FLUID PUMP COVER CLEANING AND INSPECTION
Fig. 61: Inspecting Fluid Pump Cover

Fluid Pump Cover Cleaning and Inspection

CAUTION:
Valve springs can be tightly compressed. Use care when removing retainers and plugs. Personal
injury could result.
Tip: Clean and inspect all components and machined surfaces.

1 Pressure Regulator Valve Train
2 Converter Feed Limit Valve Train
3 Pressure Relief Ball Valve and Spring
4 TCC Control Valve and Spring
1-2-3-4 and 3-5 Reverse Clutch Fluid Seal Rings
(Quantity: 3)
5
NOTE:
Do not use old seal rings. Install NEW seal rings.
Reusing old seal rings may cause internal

transmission leaks and transmission damage.
6 A/Trans Fluid Pump Locator Pin
TORQUE CONVERTER HOUSING CLEANING AND INSPECTION
Fig. 62: Cleaning Torque Converter Housing

Torque Converter Housing Cleaning and Inspection

1. Thoroughly clean the torque converter housing assembly, including threads, with clean solvent.
2. Clean sealing surfaces.
3. Inspect all threaded holes. If necessary, repair any thread damage.
1 Line Pressure Test Hole Plug
2 A/Trans Vent Pipe
Trans Fluid Cooler Pipe Fitting Seals (Quantity: 2)
3 NOTE:
Tip: Refer to Oil Cooler Pipe Seals Replacement.

TORQUE CONVERTER FLUID SEAL REPLACEMENT
Fig. 63: Replacing Torque Converter Fluid Seal

Torque Converter Fluid Seal Replacement

1 Torque Converter Fluid Seal Retaining Ring
Torque Converter Fluid Seal Assembly.
2 Special Tool:
OIL COOLER PIPE SEALS REPLACEMENT
Fig. 64: Replacing Oil Cooler Pipe Seals

Oil Cooler Pipe Seals Replacement

Trans Fluid Cooler Pipe Fitting Seals (Quantity: 2)
Special Tools
1
J 45201 Cooler Line Seal Remover. See Special
Tools.
FLUID PUMP SELECTIVE MEASUREMENT
Fig. 65: Measuring Fluid Pump Selective

Fluid Pump Selective Measurement

Pump Rotor Cavity
Tip: Measure the distance from the bottom of the gage
1
bar to the bottom of the pump rotor cavity. Refer to
Fluid Pump Selective Specifications.
A/Trans Fluid Pump Rotor
2 Tip: Refer to Fluid Pump Selective Specifications to
select the correct rotor.
A/Trans Fluid Pump Slide
3 Tip: Refer to Fluid Pump Selective Specifications to
select the correct slide.
TORQUE CONVERTER HOUSING WITH FLUID PUMP ASSEMBLE
Fig. 66: Assembling Torque Converter Housing with Fluid Pump

Torque Converter Housing with Fluid Pump Assemble

Tip: If installing a NEW pump rotor and slide into the torque converter housing, ensure to properly select
the correct rotor and slide before performing this procedure. Refer to Fluid Pump Selective
Measurement and Fluid Pump Selective Specifications.
1 Fluid Pump Slide Fluid Seal Ring
2 Fluid Pump Slide (O-Ring) Seal
3 Fluid Pump Slide Pivot Pin
Fluid Pump Slide Seal Support
4 Tip: The seal support is circular. The seal is
rectangular.
5 Slide Seal
6 Fluid Pump Slide
7 Fluid Pump Slide Outer Spring
Fluid Pump Rotor Guide
NOTE:
9
Align the rotor guide tabs to the notches on the
bottom of the rotor. Failure to do so may cause
10 Fluid Pump Rotor
11 Fluid Pump Vanes (Quantity: 13)

FLUID PUMP COVER INSTALLATION
Fig. 67: Installing Fluid Pump Cover

Fluid Pump Cover Installation

NOTE:
Refer to Fastener Notice .
Fastener Tightening Specifications: Refer to Fastener Tightening Specifications.

1 Fluid Pump Cover Assembly
Fluid Pump Cover Bolts M6 x 40 (Quantity: 13)
2
Tip: Hand tighten only.
Alignment Tool and Bolt
Tip:
1. Center the J 46664 around the fluid pump cover

3
assembly in the 9 o'clock position and tighten the
alignment bolt. See Special Tools.
2. Tighten the fluid pump cover bolts in the sequence
shown.
Tighten: 11 N.m (97 lb in)
Special Tool:
J 46664 Pump Cover Alignment Tool. See Special
Tools.
NEW 1-2-3-4 and 3-5 Reverse Clutch Housing Thrust

4
Washer
CONTROL VALVE BODY ASSEMBLY DISASSEMBLE
Input and Output Speed Sensor Assembly Removal
Fig. 68: Removing Input and Output Speed Sensor Assembly

Input and Output Speed Sensor Assembly Removal

Speed Sensor Electrical Connector
2
Tip: Release the connector lock before disconnecting.
A/Trans Input and Output Speed Sensor Wiring
4 Harness Clip (Quantity: 2)
Tip: Inspect the clips and replace if damaged.
Manual Shaft Detent Assembly and Manual Shift Shaft Position Switch Removal
Fig. 69: Removing Manual Shaft Detent Assembly and Manual Shift Shaft Position Switch
Manual Shaft Detent Assembly and Manual Shift Shaft Position Switch Removal
1 Bolt M6 x 14.5
2 Manual Shaft Detent Assembly
3 Bolt M5 x 55
A/Trans Manual Shift Shaft Position Switch
4 Assembly Electrical Connector
Tip: Release the connector lock before disconnecting.
5
Assembly
Control Solenoid Valve Assembly Removal
Fig. 70: Removing Control Solenoid Valve Assembly

Control Solenoid Valve Assembly Removal

Control Solenoid (w/Body and TCM) Valve Assembly
NOTE:
4 Use care when handling the control valve body
assembly. If dropped, damage to the control solenoid
valve body assembly internal components, including
the transmission control module (TCM), may result.
Filter Plate Assembly
NOTE:
Use care when removing or installing the filter plate
assembly. A broken or missing retaining tab may not
5 adequately secure the filter plate to the control
solenoid valve assembly, resulting in possible
damage or contamination.
NOTE:
Discard the filter plate. Replace with a NEW filter plate.
Reusing an old filter plate may cause damage to the

control solenoid valve assembly.
Upper and Lower Valve Bodies Disassemble
Fig. 71: Disassembling Upper and Lower Valve Bodies

Upper and Lower Valve Bodies Disassemble

3 Bolt M5 x 55
Control Valve Lower Body Assembly
Tip:
4 Separate the upper and lower valve bodies by

carefully prying at the point indicated.
Refer to Control Valve Lower Body Assembly
Cleaning and Inspection.
Control Valve Body Spacer (w/Gasket) Plate Assembly
5 NOTE:
Do not use the old spacer plate. Install a NEW spacer
plate. Reusing an old spacer plate may cause internal
transmission leaks and transmission damage.

Control Valve Body Ball Check Valve (Quantity: 7)
6
Tip: Note the position of the ball check valves.
Control Valve Upper Body Assembly
7 Tip: Refer to Control Valve Upper Body Assembly
Cleaning and Inspection.
CONTROL VALVE LOWER BODY ASSEMBLY CLEANING AND INSPECTION
Fig. 72: Cleaning Control Valve Lower Body Assembly

Control Valve Lower Body Assembly Cleaning and Inspection

CAUTION:
Tip: Clean and inspect all valve components and the valve body. The control valve lower body is
replaceable only as an assembly.
1 Clutch Piston Dam Feed Regulator Valve Train
2 Clutch Select Solenoid Valve Train
3 Clutch Select Solenoid Valve Train
4 Manual Valve
5 TCC Regulator Apply Valve Train
CONTROL VALVE UPPER BODY ASSEMBLY CLEANING AND INSPECTION
Fig. 73: Cleaning Control Valve Upper Body Assembly

Control Valve Upper Body Assembly Cleaning and Inspection

CAUTION:
NOTE:
Do not remove the clutch piston exhaust blow off ball plug, valve, or spring. The plug is set to a
precise depth. Replacement of this plug could cause internal transmission damage.
Tip: Clean and inspect all valve components, locating pins, and the valve body. The control valve upper
body is replaceable only as an assembly.
1 Clutch Boost Valve Train
2 1-2-3-4 Clutch Regulator Valve Train
3 3-5 Reverse Clutch Regulator Valve Train
5 2-6 Clutch Regulator Valve Train
1/Reverse Band and 4-5-6 Clutch Regulator Valve

7
Train
8 Actuator Feed Limit Valve Train
CONTROL VALVE BODY ASSEMBLY ASSEMBLE
Upper to Lower Control Valve Body Assemblies Assemble
Fig. 74: Assembling Control Valve Body Assembly

Upper to Lower Control Valve Body Assemblies Assemble

NOTE:

Control Valve Body Ball Check Valve (Quantity: 7)
1
Tip: Refer to Ball Check Valve Locations.
Control Valve Body Spacer (w/Gasket) Plate
Assembly
NOTE:
Do not use the old spacer plate. Install a NEW
2 spacer plate. Reusing an old spacer plate may
cause internal transmission leaks and
Control Valve Lower Body Assembly
3 Tip: Turn the valve body assembly over after
installing to upper body.
4
Tighten: Tighten the bolts in the sequence shown to 8
N.m (71 lb in).
Filter Plate Installation
Fig. 75: Installing Filter Plate

Filter Plate Installation

Filter Plate Assembly
NOTE:
Use care when handling the control valve body
assembly. If dropped, damage to the control
solenoid valve body assembly internal
components, including the transmission control

module (TCM), may result.
NOTE:
Discard the filter plate. Replace with a NEW filter
plate. Reusing an old filter plate may cause
damage to the control solenoid valve assembly.
1
Tip: Use care when removing or installing the filter

plate assembly. However, if a retaining tab is broken
or missing, DO NOT replace the control solenoid
valve assembly. The filter plate assembly can still be
adequately aligned.
Control Solenoid Valve Assembly Installation
Fig. 76: Installing Control Solenoid Valve Assembly

Control Solenoid Valve Assembly Installation

Control Solenoid (w/Body and TCM) Valve
1 Assembly
Tip: Note the locator pin on the control valve
lower body assembly while aligning the control
solenoid valve assembly.

2
3
4
Manual Shift Shaft Position Switch Installation
Fig. 77: Installing Manual Shift Shaft Position Switch

Manual Shift Shaft Position Switch Installation

1
Assembly
Manual Valve Link
2 Tip: Align the switch activator slide with the manual
valve link.
Bolt M5 x 55
3
A/Trans Manual Shift Shaft Position Switch Harness

Clip
Tip: The wiring harness clip on the manual shift shaft
position switch does not need to be replaced if

damaged or missing. The clip functions only as a
4 manufacturing assembly aid to keep the harness clear
during an automated bolt installation process. If the
clip is damaged, simply remove and discard.
A/Trans Manual Shift Shaft Position Switch Electrical
Connector
5 Tip: Connect and lock the manual shift shaft position
switch electrical connector to the control solenoid
valve assembly.
Valve Body, Control Solenoid Torque Sequence
Fig. 78: Control Solenoid Torque Sequence

Valve Body, Control Solenoid Torque Sequence

NOTE:
NOTE:
Bolt torque sequencing is critical to the proper function of the control solenoid valve assembly.
Failure to follow the required sequencing may result in transmission malfunction.
Tip:
1. Hand tighten the last 6 bolts before final torque sequence.

2. The 2 "heat sink" bolts must be tightened last.
1 Bolts M5 x 45 (Quantity: 5)
Bolt M5 x 55
2
Tighten: Tighten all 18 bolts in the sequence
shown to 8 N.m (71 lb in).
Control Solenoid Valve Assembly Contact Gap Inspection
Fig. 79: Inspecting Control Solenoid Valve Assembly Contact Gap

Control Solenoid Valve Assembly Contact Gap Inspection

Control Solenoid (w/Body and TCM) Valve

Assembly
1 Tip: Inspect the contact area between the "heat
sink" area of the control solenoid valve assembly
and the valve body. There should be no visible
gap. If a gap exists, loosen all 18 bolts and
retighten in the required sequence.
Input and Output Speed Sensor Assembly Installation
Fig. 80: Installing Input and Output Speed Sensor Assembly

Input and Output Speed Sensor Assembly Installation

NOTE:

A/Trans Input and Output Speed Sensor Wiring
Harness Clip (Quantity: 2)
1
Tip: Inspect the 2 wiring harness clips for
damage. Replace if damaged.
A/Trans Input and Output Speed Sensor
2
Assembly
3
Tighten: Tighten bolts to 12 N.m (106 lb in)
CENTER SUPPORT, OUTPUT CARRIER AND OUTPUT SHAFT INSTALLATION
Fig. 81: Installing Output Carrier and Output Shaft

Center Support, Output Carrier and Output Shaft Installation

Output Carrier Assembly and Output Shaft Assembly
NOTE:
Apply automatic transmission fluid (ATF) to the inside
diameter of the output shaft seal before installing the
output shaft assembly into the case. Failure to lube
the seal may cause the seal to roll during output shaft
installation, which will result in transmission damage.
2 NOTE:
Ensure the DT 47786 is completely threaded into the
output shaft assembly. Due to the weight of the
assembly, incomplete threading may cause the
assembly to break free from the DT 47786, causing
component damage.
Special Tool:
DT 47786 Output Carrier/Shaft Lifting Tool. See
Special Tools.
Center Support Assembly

Tip:
When the center support assembly is properly

3 installed, the fluid passages should align with the
fluid passage seal bores in the case assembly.
It may be necessary to rotate the output shaft by
hand in order to fully install the center support
assembly.
Center Support Retaining Ring
CAUTION:
Use care when removing or installing the retaining
ring. Ensure the J 45126 and DT 47773 are installed
properly onto the retaining ring or bodily injury may
occur.
NOTE:
4 Ensure the retaining ring is installed with the tapered
side up, and in the 9 o'clock position from the pan
side of the case. Failure to properly install the
retaining ring will cause transmission damage.
Special Tools
DT 47773 Snap Ring Pliers Adapter Set. See

Special Tools.
J 45126 Snap Ring Pliers
1-2-3-4 AND 3-5 REVERSE CLUTCH ASSEMBLY AND 4-5-6 CLUTCH ASSEMBLY
INSTALLATION
Fig. 82: Installing 1-2-3-4 And 3-5 Reverse Clutch Assembly And 4-5-6 Clutch Assembly
1-2-3-4 and 3-5 Reverse Clutch Assembly and 4-5-6 Clutch Assembly Installation
2-6 and 3-5 Reverse Clutch Hub Thrust Bearing
1
Assembly
2-6 and 3-5 Reverse Clutch (with Output Carrier
2
Outer Sun Gear Shaft) Hub Assembly
1-2-3-4 Clutch (with Output Carrier Inner Sun
4
Gear Shaft) Hub Assembly
4-5-6 Clutch (with Output Carrier Shaft and
Dampener) Hub Assembly
6
Tip: Refer to 4-5-6 Clutch Dampener Overhaul
for complete inspection.
8 4-5-6 (with Turbine Shaft) Clutch Assembly
Input Sun Gear Thrust Bearing
9 Tip: Thrust bearing snaps onto input carrier
assembly.
12 Input Sun Gear

1-2-3-4 and 3-5 Reverse Clutch Assembly
Tip: Wiggle the DT 47781 in order to align the 1-
2-3-4 and 3-5 reverse clutch plates with the
external splines of the 4-5-6 clutch assembly. See
Special Tools. To verify that the 1-2-3-4 and 3-5
13 reverse clutch assembly is fully installed, lift up
on the turbine shaft. There should not be any
noticeable slack.
Special Tool:
DT 47781 C1234 35R Clutch Assembly Installer.
See Special Tools.
TORQUE CONVERTER HOUSING WITH FLUID PUMP INSTALLATION
Fig. 83: Installing Torque Converter Housing with Fluid Pump

Torque Converter Housing with Fluid Pump Installation

NOTE:

1 NEW Fluid Pump Seal
Torque Converter (with Fluid Pump) Housing
Assembly
NOTE:
2 Ensure the turbine shaft (O-ring) seal is not
installed prior to installing the torque converter
housing assembly. The seal may become cut or
damaged during installation of the torque
converter housing assembly.
Bolts M10 x 50 (Quantity: 9)
3
Tighten: 72 N.m (53 lb ft) in the sequence
shown.
4 NEW Turbine Shaft (O-Ring) Seal
CASE EXTENSION SEAL REPLACEMENT
Fig. 84: Replacing Case Extension Seal

Case Extension Seal Replacement

Output Shaft Seal Assembly
Special Tools
1
J 38693 Seal Installer. See Special Tools.
CONTROL VALVE BODY ASSEMBLY INSTALLATION
Fig. 85: Installing Control Valve Body Assembly

Control Valve Body Assembly Installation

NOTE:

1 NEW Fluid Pump Seal Assembly
2 NEW Fluid Pump Seal Assembly
NEW Center Support Fluid Passage Seal
3
Assembly
Control Valve Body Assembly
4 Tip: Align the manual shift shaft position switch
activator slide with the detent lever guide pin.
5
Tighten: 8 N.m (71 lb in) in the sequence shown.
AUTOMATIC TRANSMISSION ELECTRICAL CONNECTOR PASSAGE SLEEVE INSTALLATION
Fig. 86: Installing Automatic Transmission Electrical Connector Passage Sleeve

Automatic Transmission Electrical Connector Passage Sleeve Installation

1 NEW Lip Seal
2 NEW O-Ring Seals (Quantity: 2)
Specification: 14-16 mm
Special Tools
DT 47715 Electrical Connector Passage Sleeve

Remover/Installer. See Special Tools.
NOTE:
3 Orientate the alignment tab inside the passage sleeve with the
slot in the electrical connector of the control solenoid valve
assembly. Push the sleeve straight into the case bore and
connector. Do NOT rotate the sleeve at any time. Ensure the
sleeve is fully seated into the case. When the sleeve is properly
installed, the distance from the case surface to the end of the
sleeve should be 14-16 mm. Even though the correct electrical
connections may still be maintained, failure to ensure proper
installation of the sleeve may result in a fluid leak around the
sleeve lip seal and into the sleeve cavity.
Electrical Connector Slide Lock
4 Tip: Push down on the electrical connector slide lock to ensure
proper installation.
FLUID FILTER AND MANUAL SHIFT DETENT ASSEMBLY INSTALLATION
Fig. 87: Installing Fluid Filter and Manual Shift Detent Assembly
Fluid Filter and Manual Shift Detent Assembly Installation

NOTE:

Manual Shaft Detent Assembly
NOTE:
1 Ensure the manual shaft detent assembly roller is
centered over the manual shaft detent lever
assembly. Failure to center the roller may cause
hard or no shift lever operation.
Bolt M6 x 14.5
2
Tighten: 12 N.m (106 lb in).
NEW Fluid Filter Seal Assembly
Special Tools
3
4 NEW Fluid Filter Assembly
TRANSMISSION FLUID PAN INSTALLATION
Fig. 88: Installing Transmission Fluid Pan

Transmission Fluid Pan Installation

NOTE:

Fluid Pan Gasket
Tip: The fluid pan gasket is reusable. Inspect the
1 gasket to determine if it may be reused. If the
gasket is stuck to the case or pan, it should be
replaced.
2 Fluid Pan Assembly
Fluid Pan Bolts M6 x 20 (Quantity: 18)
3
Tighten: 9 N.m (80 lb in) in sequence shown.
CASE EXTENSION ASSEMBLY INSTALLATION
Fig. 89: Installing Case Extension Assembly

Case Extension Assembly Installation

NOTE:

1 Case Extension
Case Extension Studs (Quantity: 2)
2
Tighten: 15 N.m (11 lb ft)
3
Tighten: 50 N.m (37 lb ft) in the sequence
shown.
TORQUE CONVERTER INSTALLATION AND HOLDING FIXTURE REMOVAL
Fig. 90: Removing Torque Converter Installation and Holding Fixture

Torque Converter Installation and Holding Fixture Removal

Callout Procedure
Tip: Rotate the transmission so that the fluid pan assembly is down.
Transmission Case Assembly
Special Tools
DT 47605 Holding Fixture Adapter. See Special

Tools.
1
J 3289-20 Holding Fixture Base Assembly
J 8763-B Holding Fixture
DESCRIPTION AND OPERATION

TRANSMISSION ID INFORMATION
Fig. 91: Identifying Transmission ID Information


1 Model Year
2 Model Code
3 Transmission Family
4 Transmission Assembly Number
5 Julian date
6 Sequential Serial Number
7 Source Code
8 Broadcast Code
9 Bar Code
10 Transmission I.D.
AUTOMATIC TRANSMISSION HYDRAULIC DIAGRAMS
Park - Engine Running
When the gear selector lever is in the Park (P) position, fluid is drawn into the pump through the transmission
fluid filter assembly, from the transmission fluid pan assembly. Line pressure is then directed to the following
valves:
Fluid Pressure Directed in Preparation for a Shift
Manual Valve
Mechanically controlled by the gear selector lever, the manual valve is in the Park (P) position and prevents line
pressure from the pressure regulator valve from entering the reverse and drive circuits.
CBR1/C456 Pressure Control (PC) Solenoid 3
The CBR1/C456 pressure control solenoid (PCS) is energized (HIGH) allowing actuator feed limit fluid to enter
the PCS CBR1/C456 CL fluid circuit. PCS CBR1/C456 CL fluid is then routed through orifice #31 to the 4-5-6
clutch boost valve and through orifice #39 to the CBR1/ C456 clutch regulator valve.
CBR1/C456 Clutch Regulator Valve
PCS CBR1/C456 CL fluid at the CBR1/C4-5-6 clutch regulator valve moves the valve against CBR1/C4-5-6
clutch regulator spring force and CBR1/FDBK fluid. This allows line pressure to pass through the valve and
enter the CBR1/456CL FD circuit. CBR1/456CL FD is then routed to clutch select valve 2.
Shift Solenoid 1
Shift solenoid 1 is energized (ON) allowing actuator feed limit fluid to enter the solenoid 1 circuit. Solenoid 1
fluid is routed to the #2 ball check valve and through orifice #10 to the torque converter clutch (TCC) regulator
valve and shuttle valve (SHTL).
TCC Regulator Valve and Shuttle Valve
Solenoid 1 fluid is routed to the TCC regulator valve and shuttle valve and moves the valve against TCC
regulator valve spring force.
#2 Ball Check Valve
Solenoid 1 fluid seats the #2 ball check valve against the reverse fluid passage and fluid is forced through
orifice #22 into the CSV2 enable fluid circuit.
Clutch Select Valve 2
CSV2 enable fluid is routed to the clutch select valve 2 and moves the valve against clutch select valve 2 spring
force. This allows CBR1/456 CL FD fluid to pass through the valve and enter the CBR1/CBR FD circuit.
CBR1/CBR FD fluid is then routed: to clutch select valve 3, into the CBR1 fluid circuit and, through orifice #49
where it enters the CBR fluid circuit and an exhaust passage at the clutch select valve 3 (this fluid is intended to
keep the low and reverse clutch full of fluid but not pressurized). CBR1 fluid is then routed to the low & reverse
clutch assembly in preparation for a shift into low or reverse gear.
Shift Solenoid 2
Shift solenoid 2 is energized (ON) allowing actuator feed limit fluid to enter the solenoid 2 fluid circuit and is
then routed to the #3 ball check valve.
3-5 Reverse Clutch Regulator Valve
Actuator feed limit fluid is routed through the valve and into the PS1 fluid passage. PS1 fluid is then sent to the
normally closed #1 pressure switch and opens the switch.
#3 Ball Check Valve
Solenoid 2 fluid seats the #3 ball check valve against 456 CL fluid passage and fluid is forced through orifice
#20 into the CSV3 enable fluid circuit. CSV3 enable fluid is then routed to the clutch select valve 3.
Clutch Select Valve #3
CSV3 enable fluid moves the clutch select valve 3 against clutch select valve 3 spring force. CBR fluid at the
clutch select valve 3 passes through the valve and exhausts.
Fig. 92: Park - Engine Running

Reverse
When the gear selector lever is moved to the Reverse (R) position (from the Park position) the normally high
C35R pressure control solenoid 2 is commanded ON and the following changes occur in the transmission's
hydraulic and electrical systems:
Fluid Pressure Directed in Preparation for a Shift
Manual Valve
With the manual valve in the reverse position, line pressure is directed into the reverse fluid circuit to the #2
ball check valve and clutch select valve 3.
#2 Ball Check Valve
Reverse fluid seats the #2 ball check valve against the solenoid 1 fluid passage and fluid is forced through
orifice #22 into the CSV2 enable circuit.
CSV2 enable fluid, present at the valve from Park position, continues to hold the clutch select valve 2 against
clutch select valve 2 spring force.
Low & Reverse Clutch Applies
Reverse fluid from the manual valve is routed to clutch select valve 3 to combine with clutch select valve 3
spring force to keep the valve in the off position. This allows reverse fluid to pass through the valve and enter
the 3-5 clutch reverse feed circuit. The 3-5 clutch reverse feed fluid from the clutch select valve 3 is also routed
to #5 ball check valve. CBR1/CBR FD fluid is also directed through the clutch select valve 3 to the low and
reverse clutch assembly.
Low & Reverse Clutch
CBR & CBR1 fluid pressures are routed to both the inner and outer areas of the low and reverse clutch piston to
hold the piston against spring force and hold the low and reverse clutch plates. The clutch was already applied
in Park, but is applied with more holding capacity in Reverse (both piston areas are pressurized).
#5 Ball Check Valve
The 3-5 clutch reverse feed fluid seats #5 ball check valve against the drive 1-6 circuit allowing 3-5 clutch
reverse feed fluid to enter the 3-5 reverse supply circuit. The 3-5 reverse supply fluid is then routed to #7 ball
check valve and through orifice #25 where is enters the 3-5 reverse feed circuit. The 3-5 reverse feed passes
through orifice #46 and then is routed to the 3-5 reverse clutch regulator valve.
3-5 Reverse Clutch Applies
C35R Pressure Control Solenoid 2
The C35R pressure control solenoid 2 is energized (HIGH) allowing actuator feed limit fluid to enter the PCS 3-
5 reverse clutch circuit. PCS 3-5 reverse clutch fluid is then routed through orifice #48 to the 3-5 reverse clutch
regulator valve and through orifice #40 to the 3-5 reverse boost valve.
PCS 3-5 reverse clutch fluid moves the 3-5 reverse clutch regulator valve against 3-5 reverse clutch regulator
valve spring force and 3-5 reverse clutch feedback fluid. This allows 3-5 reverse feed to pass through the valve
and enter the 3-5 reverse clutch circuit. The 3-5 reverse clutch fluid is then routed to the 3-5 reverse clutch and
the 3-5 reverse boost valve. PS1 fluid from pressure switch 1 exhausts through the valve allowing the switch to
close.
3-5 Reverse Boost Valve
PCS 3-5 reverse clutch fluid pressure acts on a differential area moving the 3-5 reverse clutch boost valve
against the 3-5 reverse clutch boost valve spring. The 3-5 reverse clutch fluid passes through the valve and
enters the 3-5 reverse clutch feedback circuit. As PCS 3-5 reverse clutch fluid pressure is increased to a given
value, the 3-5 reverse clutch boost valve opens the 3-5 reverse clutch feedback circuit to exhaust. This results in
the 3-5 reverse clutch regulator valve moving to the full feed position sending full 3-5 clutch reverse feed
pressure (full line pressure) to the clutch.
3-5 Reverse Clutch
The 3-5 reverse clutch fluid enters the 1-2-3-4 & reverse clutch housing to move the piston against spring force
and compensator feed fluid to apply the 3-5 reverse clutch plates.
Fig. 93: Reverse

Neutral - Engine Running
When the gear selector is moved to the Neutral (N) position, the hydraulic and electrical system operation is
identical to Park (P) range. However, if Neutral is selected after the vehicle was operating in Reverse (R), the
normally high C35R pressure control solenoid 2 is commanded OFF and the following changes would occur in
the hydraulic system:
3-5 Reverse Clutch Releases
Manual Valve
The manual valve is moved to the Neutral position and blocks line pressure from entering the reverse and drive
fluid circuits. The reverse fluid from the #2 ball check valve and clutch select valve 3 is opened to an exhaust
passage at the manual valve.
The C35R pressure control solenoid 2 is commanded OFF allowing PCS 3-5 reverse clutch fluid from the 3-5
reverse clutch boost valve and 3-5 reverse clutch regulator valve to exhaust.
3-5 Reverse Clutch Boost Valve
The 3-5 reverse boost valve spring force moves the valve to allow 3-5 reverse clutch feedback fluid from the 3-
5 reverse clutch regulator valve to enter the 3-5 reverse clutch circuit and exhaust.
The 3-5 reverse clutch regulator valve spring force moves the valve to allow 3-5 reverse clutch fluid from the 3-
5 reverse clutch and clutch select valve 2 to pass through the valve and enter the exhaust backfill fluid circuit.
The 3-5 reverse clutch fluid then enters the exhaust backfill fluid circuit and is routed through orifice #30 to the
exhaust backfill pressure relief valve where excess pressure is exhausted.
3-5 Reverse Clutch
The 3-5 reverse clutch spring force combined with a force from the compensator moves the 3-5 reverse clutch
piston to release t h e 3-5 reverse clutch plates and force 3-5 reverse clutch fluid to exhaust from the 1-2-3-4 and
3-5 reverse clutch housing. The 3-5 reverse clutch fluid is then routed to the 3-5 reverse clutch regulator valve
allowing the 3-5 reverse clutch to release.
When reverse fluid exhausts through the manual valve, CSV3 enable fluid moves the valve against clutch select
valve 3 spring force. The 3-5 reverse feed fluid is routed around #7 ball check valve and into the 3-5 reverse
supply circuit. The 3-5 reverse supply fluid is routed around #5 ball check valve and into the 3-5 clutch reverse
feed circuit and exhausts at the clutch select valve 3.
Fig. 94: Neutral - Engine Running

Drive Range, First Gear Engine Braking
When the gear selector lever is moved to the Drive (D) range from the Neutral (N) position, the transmission
will provide engine braking. In this operating range, the normally-low C1234 pressure control solenoid 5 is
commanded ON and in the engine braking mode the following changes occur within the hydraulic circuits:
Fluid Pressure is Directed to the 1-2-3-4 Clutch and the Low & Reverse Clutch to Provide Engine Braking
Manual Valve
The manual valve is moved to the Drive (D) position and allows line fluid pressure to enter the drive fluid
circuit. Drive fluid is then routed to the clutch select valve 2.
Drive fluid at the clutch select valve 2 passes through the valve and enters the drive brake circuit. Drive brake
fluid is then routed to the clutch select valve 3.
Drive brake fluid at the clutch select valve 3 passes through the valve and enters the Drive B fluid circuit. Drive
B fluid is then routed to #1 ball check valve.
#1 Ball Check Valve
Drive B fluid seats the #1 ball check valve against drive 1-6 fluid to force drive B fluid into the CB26/C1234
feed passage. CB26/ C1234 feed fluid is routed to the #6 ball check valve, through orifice #43 and, to the 2-6
clutch regulator valve. CB26/C1234 feed fluid passes through the 2-6 clutch regulator valve and enters the
pressure switch 3 (PS3) fluid circuit. PS3 fluid is then routed to the normally closed pressure switch 3 and opens
the switch.
#6 Ball Check Valve
CB26/C1234 feed fluid seats the #6 ball check valve against the 1234 clutch feed passage forcing CB26/C1234
feed fluid through orifice #32 before entering the 1234 clutch feed circuit. The 1234 clutch feed fluid is routed
through orifice #33 and then to the 1-2-3-4 clutch regulator valve.
1-2-3-4 Clutch Applies
C1234 Pressure Control Solenoid 5
The C1234 pressure control solenoid 5 is commanded ON allowing actua #35 to the 1-2-3-4 clutch regulator
valve. PCS1234 clutch fluid is also routed through orifice #29 and then to the 1-2-3-4 clutch boost valve.
1-2-3-4 Clutch Regulator Valve
PCS1234 clutch fluid moves the 1-2-3-4 clutch regulator valve against 1-2-3-4 clutch regulator valve spring
force to allow 1234 clutch feed fluid to pass through the valve and enter the 1234 clutch fluid circuit. The 1234
clutch fluid is then routed to the 1234 clutch boost valve and the 1-2-3-4 clutch.
1-2-3-4 Clutch Boost Valve
PCS1234 clutch fluid pressure acts on a differential area moving the 1234 clutch boost valve against the 1234
clutch boost valve spring. The 1234 clutch fluid passes through the valve and enters the 1234 clutch feedback
circuit. As PCS 1234 clutch fluid pressure is increased to a given value, the 1234 clutch boost valve opens the
1234 clutch feedback circuit to exhaust. This results in the 1234 clutch regulator valve moving to the full feed
position sending full 26 CL/1234 CL feed pressure (full line pressure) to the clutch.
1-2-3-4 Clutch
The 1234 clutch fluid enters the 1234 clutch housing to move the piston against spring force and compensator
feed fluid to apply the 1-2-3-4 clutch plates.
Fig. 95: Drive Range, First Gear Engine Braking

Drive Range, First Gear
As the vehicle speed increases, the transmission control module (TCM) receives input signals from the
automatic transmission input and output speed sensors, throttle position sensor and other vehicle sensors to
determine the precise moment to de-energize or "turn off" shift solenoid 1 and command OFF the normally-
high CBR1/C456 pressure control solenoid 3.
Low & Reverse Clutch Releases
Shift Solenoid 1
When shift solenoid 1 is "turned OFF", CSV2 enable fluid from the clutch select valve 2 passes by the #2 ball
check valve and enters the solenoid 1 fluid circuit. Solenoid 1 fluid from the #2 ball check valve and TCC
regulator valve is then routed to the solenoid where it exhausts.
Clutch select valve 2 (CSV2) enable fluid is exhausted from the clutch select valve 2 and clutch select valve 2
spring force moves the valve to the released position. With clutch select valve 2 in the released position, drive
fluid from the manual valve passes through the valve and enters the drive 1-6 fluid circuit. Drive 1-6 fluid then
feeds all clutch regulator valves and the TCC regulator valve.
CBR1/C456 Pressure Control Solenoid 3
The CBR1/C456 pressure control solenoid 3 is commanded OFF allowing PCS CBR1/C456 fluid from the
CBR1/C456 clutch regulator valve and 456 clutch boost valve to exhaust.
CBR1/C456 clutch regulator valve spring force moves the valve to exhaust the CBR1/456 clutch feed circuit
and allow drive 1-6 fluid to enter the PS5 fluid circuit. PS5 fluid is then routed to the normally-closed pressure
switch 5 and opens the switch. PS5 fluid is also routed to the #4 ball check valve and flows into the CSV2 latch
fluid circuit.
#4 Ball Check Valve
PS5 fluid pressure seats the #4 ball check valve against the 456 clutch fluid circuit. PS5 fluid is then directed
into the CSV2 latch fluid circuit and routed to the clutch select valve 2. CSV2 latch fluid combines with clutch
select valve 2 spring force and holds the valve in this position during all 6 forward gear ranges.
#5 Ball Check Valve
Drive 1-6 fluid pressure seats the #5 ball check valve against the 35 clutch reverse feed fluid passage. Drive 1-6
fluid is then directed into the 35R supply fluid circuit which is routed to the #7 ball check valve and orifice #25.
#7 Ball Check Valve
The 35R supply fluid seats the #7 ball check valve against the 35R feed fluid passage to force 35R supply fluid
through orifice #25 before entering the 35R feed circuit. The 35R feed fluid is then routed to the 3-5 reverse
clutch regulator valve.
Low and Reverse Clutch
Low and reverse clutch spring force moves the low and reverse clutch piston which forces clutch braking
(CBR) and CBR1 fluid out of the center support. CBR fluid is routed to the clutch select valve 3 where it
exhausts. CBR1 fluid is routed to the clutch select valve 2 where it exhausts. The low and reverse clutch is in
the released position.
Fig. 96: Drive Range, First Gear

Drive Range, Second Gear
automatic transmission input and output speed sensors, the throttle position sensor and other vehicle sensors to
determine the precise moment to command ON the normally-low pressure control solenoid 4.
Second Clutch Applies
CB26 Pressure Control Solenoid 4
The CB26 pressure control solenoid 4 is commanded ON, allowing actuator feed limit fluid to enter the pressure
control solenoid (PCS) 26 clutch fluid circuit. PCS 26 clutch fluid is then routed through orifice #44 to the 2-6
clutch regulator gain valve.
2-6 Clutch Regulator Gain Valve
The 2-6 clutch regulator gain valve allows the gain (valve input to output pressure magnification factor) of the
2-6 clutch regulator valve to be different for a 1-2 shift verses a 5-6 shift. For a 1-2 shift, PCS 26 clutch fluid
pressure acts on a differential area resulting in the "high gain" pressure output.
2-6 Clutch Regulator Valve
PCS 26 clutch fluid moves the 2-6 clutch regulator / gain valve assembly against the 2-6 clutch regulator valve
spring force to allow 26 clutch/1234 clutch feed fluid to pass through the valve. The 26 clutch/1234 clutch feed
fluid is routed into the 26 clutch fluid circuit where it passes through orifice #41 and then to the spring end of
the 2-6 clutch regulator valve, and to the 2-6 clutch within the center support.
2-6 Clutch
The 26 clutch fluid from the 2-6 clutch regulator valve is routed through the center support and to the 2-6 clutch
piston assembly. The 26 clutch fluid pressure moves the piston against 2-6 clutch spring force to apply the 2-6
clutch plates.
Fig. 97: Drive Range, Second Gear

Drive Range, Third Gear
determine the precise moment to command OFF the normally-low CB26 pressure control solenoid 4. At the
same time the C35R pressure control solenoid 2 is also commanded ON to regulate 3-5 clutch apply.
The C35R pressure control solenoid 2 is commanded ON allowing actuator feed fluid to enter the pressure
control solenoid (PCS) 35 reverse clutch fluid circuit. PCS 35 reverse clutch fluid is routed through orifice #48
and then to the 3-5 reverse clutch regulator valve. PCS 35 reverse clutch fluid is also routed through orifice #40
and then to the 3-5 reverse clutch boost valve.
PCS 35 reverse clutch fluid pressure acts on a differential area moving the 3-5 reverse clutch boost valve
against the 3-5 reverse clutch boost valve spring. The 35 reverse clutch fluid passes through the valve and enters
the 35 reverse clutch feedback circuit. As PCS 35 reverse clutch fluid pressure is increased to a given value, the
3-5 reverse clutch boost valve opens the 35 reverse clutch feedback circuit to exhaust. This results in the 3-5
reverse clutch regulator valve moving to the full feed position sending full 35 reverse clutch feed pressure (full
line pressure) to the clutch.
PCS 35 reverse clutch fluid moves the 3-5 reverse clutch regulator valve against 3-5 reverse clutch regulator
valve spring force and 35 reverse clutch feedback fluid. This allows 35 reverse feed to pass through the valve
and enter the 35 reverse clutch circuit. The 35 reverse clutch fluid is then routed to the 3-5 reverse clutch, the 3-
5 reverse boost valve and the clutch select valve 2. When the 3-5 reverse clutch regulator valve is in this
position, PS1 fluid from the pressure switch 1 exhausts through the valve allowing the switch to close.
3-5 Reverse Clutch
The 35 reverse clutch fluid enters the 1-2-3-4 & 3-5 reverse clutch housing to move the piston against spring
force combined with force from the compensator to apply the 3-5 reverse clutch plates.
2-6 Clutch Releases
The CB26 pressure control solenoid 4 is commanded OFF allowing PCS 26 clutch fluid from the 2-6 clutch
regulator valve to exhaust. The 26 clutch/1234 clutch feed fluid at the 2-6 clutch regulator valve passes through
the valve and enters the PS3 fluid circuit. PS3 fluid is then routed to pressure switch 3 and opens the normally-
closed switch.
The 2-6 clutch regulator valve spring force moves the valve to allow 26 clutch fluid from the 2-6 clutch to pass
through the valve and enter the exhaust backfill fluid circuit.
2-6 Clutch
The 2-6 clutch spring force moves the 2-6 clutch piston to release the 2-6 clutch plates and forces 26 clutch
fluid to exhaust from the center support. The 26 clutch fluid is routed through the 2-6 clutch regulator valve
where it enters the exhaust backfill fluid circuit and is routed through orifice #30 to the exhaust backfill pressure
relief valve where excess pressure is exhausted.
Fig. 98: Drive Range, Third Gear

Drive Range, Third Gear Default
If the transmission is in 1st, 2nd or 3rd gear during a transmission electrical component failure, the transmission
will default to 3rd gear. All solenoids will default to their normal state. If the torque converter clutch was
applied, it will release. This default action will enable the vehicle to be safely driven to a service center.
1-2-3-4 Clutch Stays Applied
Shift Solenoid 2
Shift solenoid 2 defaults to it's normally-closed state (OFF), and SOL 2 fluid exhausts through the solenoid.
Solenoid 2 fluid pressure no longer holds the clutch select valve 3 open. When the valve moves back to the
closed position, it opens the 1234 clutch default fluid circuit, and 1234 default fluid is routed to the 1-2-3-4
clutch regulator valve.
With the absence of PCS 1234 clutch fluid, due to the default state of the C1234 pressure control solenoid 5, the
1-2-3-4 regulator valve would close from spring force. However, the 1234 clutch default fluid enters behind the
1-2-3-4 regulator shuttle valve and keeps the valve in the open position.
1-2-3-4 Clutch
With the 1-2-3-4 clutch regulator valve still held in the open position, the 1-2-3-4 clutch will stay applied.
3-5 Reverse Clutch Applied or Applies
The normal state for the C35R pressure control solenoid 2 is ON, therefore PSC 35 reverse clutch fluid will still
be routed to the 3-5 reverse clutch regulator valve and the 3-5 reverse clutch boost valve.
and enter the 3-5 reverse clutch circuit. 3-5 reverse clutch fluid is then routed to the 3-5 reverse clutch, the 3-5
reverse boost valve and the clutch select valve 2. When the 3-5 reverse clutch regulator valve is in this position,
PS1 fluid from the pressure switch 1 exhausts through the valve, allowing the switch to close.
PCS 3-5 reverse clutch fluid pressure acts on a differential area moving the 3-5 reverse clutch boost valve
the 3-5 reverse clutch regulator valve moving to the full feed position sending full 3-5 reverse clutch feed
3-5 Reverse Clutch
The 3-5 reverse clutch fluid enters the 1-2-3-4 & 3-5 reverse clutch housing to move the piston against spring
Fig. 99: Drive Range, Third Gear Default

Drive Range - Fourth Gear
determine the precise moment to command OFF the normally-high C35R pressure control solenoid 2. At the
same time the normally-low CBR1/C456 pressure control solenoid 3 is commanded ON to regulate 4-5-6 clutch
apply.
4-5-6 Clutch Applies
CBR1/C456 Pressure Control Solenoid 3
The CBR1/C456 pressure control solenoid 3 (PCS) is commanded ON allowing actuator feed fluid to enter the
PCS CBR1/456 clutch fluid circuit. PCS CBR1/456 clutch fluid is routed through orifice #39 to the CBR1/C456
clutch regulator valve and, through orifice #31 to the CBR1/C456 clutch boost valve.
PCS CBR1/456 clutch fluid moves the CBR1/C456 clutch regulator valve against CBR1/C456 clutch regulator
valve spring force to allow line fluid to pass through the valve an enter the CBR1/456 clutch feed circuit.
CBR1/456 clutch feed is then routed to the 4-5- 6 clutch boost valve and clutch select valve 2.
4-5-6 Clutch Boost Valve
PCS CBR1/456 clutch fluid pressure acts on a differential area moving the CBR1/456 clutch boost valve against
the CBR1/456 clutch boost valve spring. CBR1/456 clutch fluid passes through the valve and enters the
CBR1/456 clutch feedback circuit. As PCS CBR1/456 clutch fluid pressure is increased to a given value, the
CBR1/456 clutch boost valve opens the CBR1/456 clutch feedback circuit to exhaust. This results in the
CBR1/456 clutch regulator valve moving to the full feed position, sending full line pressure to the clutch.
CBR1/456 clutch feed fluid passes through the clutch select valve 2 and enters the 456 clutch feed circuit. The
456 clutch feed fluid is routed to the clutch select valve 3 where it passes through the valve and enters the 456
clutch fluid circuit. The 456 clutch fluid is routed to the 4-5-6 clutch, the 2-6 clutch regulator gain valve and to
the #3 ball check valve. The 456 clutch fluid seats the #3 ball check valve against solenoid 2 fluid passage and
directed into the CSV3 enable fluid circuit where it is routed through orifice #20 and to clutch select valve 3.
4-5-6 Clutch
The 456 clutch fluid enters the 4-5-6 clutch housing to move the piston against spring force, combined with
force from the compensator to apply the 4-5-6 clutch plates.
3-5 Reverse Clutch Releases
The C35R pressure control solenoid 2 is commanded OFF, allowing PCS 35 reverse clutch fluid from the 3-5
reverse clutch boost valve and the 3-5 reverse clutch regulator valve to exhaust through the solenoid.
The 3-5 reverse boost valve spring force moves the valve to allow 35 reverse clutch feedback fluid from the 3-5
reverse clutch regulator valve to enter the 35 reverse clutch fluid circuit and exhaust.
The 3-5 reverse clutch regulator valve spring force moves the valve to allow 35 reverse clutch fluid from the 3-
5 reverse clutch to pass through the valve and enter the exhaust backfill fluid circuit. The 35 reverse clutch fluid
then enters the exhaust backfill fluid circuit and is routed through orifice #30 to the exhaust backfill pressure
3-5 Reverse Clutch
The 3-5 reverse clutch spring force combined with force from the compensator move the 3-5 reverse clutch
piston to release the 3-5 clutch plates and forces 35 reverse clutch fluid to exhaust from 1- 2-3-4 and 3-5 reverse
clutch housing. The 35 reverse clutch fluid is then routed to the 3-5 reverse clutch regulator valve and
exhausted.
Fig. 100: Drive Range, Fourth Gear

Drive Range, Fifth Gear
determine the precise moment to command ON the normally-high C35R pressure control solenoid 2. At the
same time the normally-low C1234 pressure control solenoid 5 is commanded OFF.
The C35R pressure control solenoid 2 is commanded ON, allowing actuator feed fluid to enter the PCS 35
reverse clutch fluid circuit. PCS 35 reverse clutch fluid is routed through orifice #48 and then to the 3-5 reverse
clutch regulator valve. PCS 35 reverse clutch fluid is also routed through orifice #40 and then to the 3-5 reverse
clutch boost valve.
PCS 35 reverse clutch fluid pressure acts on a differential area moving the PCS 3-5 reverse clutch boost valve
against the 3-5 reverse clutch boost valve spring. The 35 reverse clutch fluid passes through the valve and enters
the 35 reverse clutch feedback circuit. As PCS 35 reverse clutch fluid pressure is increased to a given value, the
3-5 reverse clutch boost valve opens the 35 reverse clutch feedback circuit to exhaust. This results in the 3-5
reverse clutch regulator valve moving to the full feed position sending full 35 reverse clutch feed pressure (full
line pressure) to the clutch.
PCS 35 reverse clutch fluid moves the 3-5 reverse clutch regulator valve against 3-5 reverse clutch regulator
valve spring force and 35 reverse clutch feedback fluid. This allows 35 reverse feed to pass through the valve
and enter the 35 reverse clutch circuit. The 35 reverse clutch fluid is then routed to the 3-5 reverse clutch, the 3-
5 reverse boost valve and the clutch select valve 2. When the 3-5 reverse clutch regulator valve is in this
position, PS1 fluid from the pressure switch 1 exhausts through the valve allowing the switch to close.
The 35 reverse clutch fluid passes through the clutch select valve 2 and enters the 1234 clutch default feed fluid
circuit. The 1234 clutch default feed fluid is then routed to the clutch select valve 3.
3-5 Reverse Clutch
The 35 reverse clutch fluid enters the 1-2-3-4 & 3-5 reverse clutch housing to move the piston against spring
1-2-3-4 Clutch Releases
The C1234 pressure control solenoid 5 is commanded OFF, allowing PCS 1234 clutch fluid from the 1-2-3-4
clutch regulator valve and 1-2-3-4 clutch boost valve to exhaust.
The 1-2-3-4 clutch regulator valve spring force moves the valve to allow 1234 clutch feed fluid from the 1-2-3-
4 clutch to pass through the valve and enter the exhaust backfill fluid circuit. The 1234 clutch fluid the enters
the exhaust backfill fluid circuit and is routed through orifice #30 to the exhaust backfill pressure relief valve
where excess pressure is exhausted. Also, 1234 clutch regulator valve spring force moves the valve to allow
1234 clutch feed fluid to pass through the valve and enter the PS4 fluid circuit. PS4 fluid is then routed to
pressure switch 4 and opens the normally-closed switch.
1-2-3-4 Clutch Boost Valve
The 1-2-3-4 clutch boost valve spring force moves the valve to allow 1234 clutch feedback fluid from the 1-2-3-
4 clutch regulator valve to enter the 1234 clutch circuit and exhaust.
1-2-3-4 Clutch
The 1-2-3-4 clutch spring force combined with force from the compensator moves the 1-2-3-4 clutch piston to
release the clutch plates and force 1234 clutch fluid from the 1-2-3-4 and 3-5 reverse clutch housing. The 1234
clutch fluid is routed through the 1-2-3-4 clutch regulator valve where it enters the exhaust backfill fluid circuit.
Fig. 101: Drive Range, Fifth Gear

Drive Range, Fifth Gear Default
If the transmission is in 4th, 5th or 6th gear during a transmission electrical component failure, the transmission
will default to 5th gear. All solenoids will default to their normal state. If the torque converter clutch was
applied, it will release. The transmission will stay in 5th gear default range until the ignition has been turned off
or transmission shifted to reverse. When the vehicle is restarted, and shifted back into drive, the transmission
will then operate in the 3rd gear default range. This default action will enable the vehicle to be safely driven to a
service center.
The C35R pressure control solenoid 2 defaults to ON, allowing actuator feed fluid to enter the pressure control
solenoid (PCS) 35 reverse clutch fluid circuit. PCS 35 reverse clutch fluid is routed through orifice #48 and then
to the 3-5 reverse clutch regulator valve. PCS 35 reverse clutch fluid is also routed through orifice #40 and then
to the 3-5 reverse clutch boost valve.
PCS 3-5 reverse clutch fluid pressure acts on a differential area moving the PCS 3-5 reverse clutch boost valve
the 3-5 reverse clutch regulator valve moving to the full feed position sending full 3-5 reverse clutch feed
and enter the 3-5 reverse clutch circuit. The 3-5 reverse clutch fluid is then routed to the 3-5 reverse clutch, the
3-5 reverse boost valve and the clutch select valve 2. When the 3-5 reverse clutch regulator valve is in this
position, PS1 fluid from the pressure switch 1 exhausts through the valve, allowing the switch to close.
3-5 Reverse Clutch
The 3-5 reverse clutch fluid enters the 1-2-3-4 & 3-5 reverse clutch housing to move the piston against spring
Once the clutch select valve 3 is moved to the ON position in 4th gear, it will remain in this position throughout
the 5th gear default range, until the ignition has been turned OFF. When the ignition is OFF, fluid will exhaust
from the valve, thus when the vehicle is restarted, the transmission will then be in the 3rd gear default range.
1-2-3-4 Clutch Releases or 2-6 Clutch Releases
If the transmission was in 4th gear when an electrical condition commands a protection mode, the C1234
pressure control solenoid 5 defaults to the OFF position, allowing PCS 1234 clutch fluid from the 1-2-3-4
clutch, the 1-2-3-4 clutch regulator valve and 1- 2-3-4 clutch boost valve to exhaust.
2-6 CB26 Pressure Control Solenoid 4
If the transmission was in 6th gear when an electrical condition commands a protection mode, the CB26
pressure control solenoid 4 defaults to the OFF position, allowing PCS 26 clutch fluid from the 2-6 clutch
regulator valve, and the 2-6 clutch to exhaust.
Torque Converter Clutch Releases
TCC Pressure Control Solenoid
The torque converter clutch (TCC) pressure control solenoid will default to it's normal state, OFF. PCS TCC
fluid will exhaust from the TCC control valve, and spring force will shuttle the valve to the off position. TCC
apply fluid will then be routed to the cooler, and TCC release fluid will be routed to the torque converter for
complete TCC release.
Fig. 102: Drive Range, Fifth Gear Default

Drive Range, Sixth Gear
determine the precise moment to command ON the normally-low CB26 pressure control solenoid 4 (PCS). At
the same time the normally-high C35R pressure control solenoid 2 is commanded OFF.
2-6 Clutch Applies
The CB26 pressure control solenoid 4 is commanded ON, allowing actuator feed fluid to enter the PCS 26
clutch fluid circuit. PCS 26 fluid is routed through orifice #44 and then to the 2-6 clutch regulator gain valve.
2-6 Clutch Regulator Gain Valve
The 2-6 clutch regulator gain valve allows the gain (valve input to output pressure magnification factor) of the
2-6 clutch regulator valve to be different for a 1-2 shift verses a 5-6 shift. For a 5-6 shift PCS 26 clutch fluid
pressure passes through the hollow valve and only acts on the 26 regulator valve area, resulting in the "low
gain" pressure output.
PCS 26 clutch fluid moves the 2-6 clutch regulator/gain valve assembly against the 2-6 clutch regulator valve
spring force to allow 26 clutch/1234 clutch feed fluid to pass through the valve. The 26 clutch/1234 clutch feed
fluid is routed into the 26 clutch fluid circuit where it passes through orifice #41 and then to the spring end of
the 2-6 clutch regulator valve, and to the 2-6 clutch within the center support.
2-6 Clutch
The 26 clutch fluid from the 2-6 clutch regulator valve is routed through the center support and to the 2-6 clutch
piston assembly. The 26 clutch fluid pressure moves the piston against 2-6 clutch spring force to apply the 2-6
clutch plates.
3-5 Clutch Releases
The C35R pressure control solenoid 2 is commanded OFF, allowing PCS 35 reverse clutch fluid from the 3-5
reverse clutch boost valve and the 3-5 reverse clutch regulator valve to exhaust through the solenoid.
The 3-5 reverse boost valve spring force moves the valve to allow 35 reverse clutch feedback fluid from the 3-5
reverse clutch regulator valve to enter the 35 reverse clutch circuit and exhaust.
The 3-5 reverse clutch regulator valve spring force moves the valve to allow 35 reverse clutch fluid from the 3-
5 reverse clutch to pass through the valve and enter the exhaust backfill fluid circuit. The 35 reverse clutch fluid
then enters the exhaust backfill fluid circuit and is routed through orifice #30 to the exhaust backfill pressure
3-5 Reverse Clutch
The 3-5 reverse clutch spring force combined with force from the compensator move the 3-5 reverse clutch
piston to release the 3-5 clutch plates and forces 35 reverse clutch fluid to exhaust from 1-2-3-4 and 3-5 reverse
clutch housing. The 35 reverse clutch fluid is then routed to the 3-5 reverse clutch regulator valve where it
enters the exhaust backfill circuit.
Fig. 103: Drive Range, Sixth Gear

FLUID PASSAGES
Fig. 104: Torque Converter Housing - Fluid Pump Cover Side


2 Line
4 Converter Feed
5 Converter Feed Limit
6 TCC Release
7 TCC Apply
8 Cooler Feed
9 Center Lube
10 Regulator Apply
38 PCS TCC
49 PCS Line
51 Exhaust
52 Void
55 Vent
56 Torque Converter Seal Drainback
Fig. 105: Fluid Pump Cover - Torque Converter Housing Side


1 Suction
2 Line
4 Converter Feed
5 Converter Feed Limit
6 TCC Release
7 TCC Apply
8 Cooler Feed
9 Center Lube
10 Regulator Apply
38 PCS TCC
49 PCS Line
51 Exhaust
52 Void
55 Vent
Fig. 106: Fluid Pump Cover - Case Side


1 Suction
2 Line
9 Center Lube
10 Regulator Apply
11 Compensator Feed
14 35 Reverse Clutch
26 1234 Clutch
34 456 Clutch
38 PCS TCC
49 PSC Line
51 Exhaust
52 Void
55 Vent
Fig. 107: Case - Top Channel Plate Side


52 Void
Fig. 108: Control Valve Upper Body Assembly - Case Side


2 Line
9 Center Lube
10 Regulator Apply
11 Compensator Feed
26 1234 Clutch
29 CBR1
30 CBR
34 456 Clutch
38 PCS TCC
46 26 Clutch
49 PCS Line
51 Exhaust
52 Void
Fig. 109: Control Valve Upper Body Assembly - Bottom Channel Plate Side

2 Line
9 Center Lube
10 Regulator Apply
11 Compensator Feed
12 Actuator Feed Limit
13 Reverse
15 35 Reverse Clutch Feedback
16 CSV2 Enable
17 Solenoid 1
19 CSV3 Enable
21 Drive 1-6
24 1234 Clutch DFLT
25 1234 Clutch Feed
26 1234 Clutch
27 1234 Clutch Feedback
29 CBR1
30 CBR
31 CBR1/456 Clutch Feed
32 CBR1 Feedback
34 456 Clutch
35 CSV2 Latch
37 35 Reverse Feed
38 PCS TCC
39 PCS 1234 Clutch
40 PS4
41 PS1
42 PS3
43 PS5
44 26 Clutch/1234 CL Feed
45 PCS 35 Rev Clutch
46 26 Clutch
47 PCS 26 Clutch
48 PCS CBR1/456 Clutch
49 PCS Line
50 Exhaust BF
51 Exhaust
52 Void
53 35 R Supply
Fig. 110: Control Valve Upper Body Assembly - Control Solenoid Valve Assembly Side

17 Solenoid 1
18 Solenoid 2
38 PCS TCC
39 PCS 1234 Clutch
40 PS4
41 PS1
42 PS3
43 PS5
47 PCS 26 Clutch
49 PCS Line
51 Exhaust
52 Void
Fig. 111: Control Valve Lower Body Assembly - Control Valve Upper Body Assembly Side

2 Line
9 Center Lube
10 Regulator Apply
11 Compensator Feed
13 Reverse
16 CSV2 Enable
17 Solenoid 1
18 Solenoid 2
19 CSV3 Enable
20 Drive
21 Drive 1-6
22 Drive Brake
23 1234 Clutch DFLT Feed
24 1234 Clutch DFLT
25 1234 Clutch Feed
26 1234 Clutch

28 CBR1/CBR Feed
29 CBR1
30 CBR
32 CBR1 Feedback
33 456 Clutch Feed
34 456 Clutch
35 CSV2 Latch
36 Drive B
37 35 Reverse Feed
38 PCS TCC
39 PCS 1234 Clutch
40 PS4
41 PS1
42 PS3
43 PS5
46 26 Clutch
47 PCS 26 Clutch
49 PSC Line
50 Exhaust BF
51 Exhaust
52 Void
54 35 Clutch Reverse Feed
Fig. 112: Control Valve Body Spacer Plate Assembly - Bottom Channel Plate Side

2 Line
8 Cooler Feed
9 Center Lube
10 Regulator Apply
11 Compensator Feed
13 Reverse
16 CSV2 Enable
17 Solenoid 1
18 Solenoid 2
19 CSV3 Enable
21 Drive 1-6
24 1234 Clutch DFLT
25 1234 Clutch Feed
26 1234 Clutch
28 CBR1/CBR Feed
29 CBR1
30 CBR
32 CBR1 Feedback
34 456 Clutch
35 CSV2 Latch
36 Drive B
37 35 Reverse Feed
38 PCS TCC
39 PCS 1234 Clutch
40 PS4
41 PS1
42 PS3
43 PS5
46 26 Clutch
47 PCS 26 Clutch
49 PCS Line
50 Exhaust BF
51 Exhaust
53 35 R Supply
54 35 Clutch Reverse Feed
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Special Tools
Illustration Tool Number/Description
DT 47605
Holding Fixture Adapter
DT 47715
Remover/Installer
DT 47761
Clutch Spring Compressor
DT 47768-1
Seal Protector
DT 47768-2
Seal Pusher
DT 47768-3
Seal Sizer
DT 47770
Seal Installer
DT 47773
Snap Ring Pliers Adapter Set
DT 47778-1
Low Clutch Sprag Retaining Ring Cone
DT 47778-2
Low Clutch Sprag Retaining Ring Pusher
DT 47779
DT 47780
Low Clutch Sprag Seal Cone
DT 47781
C1234 and 35R Clutch Assembly Installer
DT 47782-1
Retaining Ring Cone
DT 47782-2
Retaining Ring Installer
DT 47786
Output Carrier/Shaft Lifting Tool
DT 47848
Seal Installer
DT 47857
Bearing Installer
DT 47865
Bearing Remover
DT 47866
Bearing Installer
DT 47867
Adjustable Clutch Spring Compressor
DT 47868-1
Pack Travel Weight
DT 47868-2
Magnetic Base Adapter
J 3289-20
Holding Fixture Base Assembly
J 46664
Pump Cover Alignment Tool
J 6125-B
Slide Hammer
J 8001
Dial Indicator Set
J 8092
Driver Handle
J 8763-B
Holding Fixture
J 23129
Universal Seal Remover
J 26900-13
Magnetic Base
J 38693
Seal Installer
J 38734
Intermediate Spring Compressor Adapter
J 42183
Driver Handle
J 43074
J 45000
Seal Remover
J 45124
Remover Bridge
J 45126
Snap Ring Pliers
J 45201
Cooler Line Seal Remover

Transmisión 6L80

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Transmisión 6L80

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Transmisión 6L80

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2006 Chevrolet Corvette Z06

2006 TRANSMISSION Automatic Transmission - 6L80 - Overhaul - Corvette

Automatic Transmission - 6L80 - Overhaul - Corvette

Fastener Tightening Specifications

Input and Output Speed

martes, 14 de febrero de 2023 07:12:07

TRANSMISSION GENERAL SPECIFICATIONS

Transmission General Specifications

FLUID CAPACITY SPECIFICATIONS

Fluid Capacity Specifications

Application Metric English

FLUID PUMP SELECTIVE SPECIFICATIONS

Fluid Pump Selective Specifications

CLUTCH BACKING PLATE RETAINING RING SPECIFICATIONS

3-5 Reverse Clutch

Fig. 1: Case and Associated Parts

Callout Component Name

11 A/Trans Electrical Connector Passage Sleeve

Fig. 2: Clutch Assemblies and Associated Parts

Callout Component Name

63 1-2-3-4 Clutch Hub Thrust Bearing Assembly

Fig. 3: Torque Converter (w/Fluid Pump) Housing Assembly

Callout Component Name

203 Torque Converter Housing - Model Dependent

Fig. 4: Control (with Body and Valve) Valve Assembly

Callout Component Name

315 A/Trans Manual Shaft Position Switch Wiring Harness Clip

Fig. 5: Upper Control Valve Body Assembly

Callout Component Name

Fig. 6: Lower Control Valve Body Assembly

Callout Component Name

Fig. 7: 1-2-3-4 and 3-5 Reverse Clutch Assembly

Callout Component Name

414 1-2-3-4 Clutch Piston

Fig. 8: 4-5-6 (w/Turbine Shaft) Clutch Assembly

Callout Component Name

433 4-5-6 Clutch Plate Assembly

Fig. 9: 2-6 Clutch Assembly

Callout Component Name

457 2-6 Clutch Piston Assembly

Fig. 10: Low and Reverse Clutch Assembly

Callout Component Name

468 Low Clutch Sprag Seal

Fig. 11: 4-5-6 Clutch Hub Assembly

Callout Component Name

Fig. 12: Output Carrier Assembly

Callout Component Name

Fig. 13: Output Shaft Assembly

Callout Component Name

Fig. 14: Park System Components

Callout Component Name

AUTOMATIC TRANSMISSION ELECTRONIC COMPONENT VIEWS

Fig. 15: Electronic Components

Callout Component Name

Fig. 16: Component Locations

Callout Component Name

487 Output Carrier Front Sun Gear

BUSHING, BEARING, AND WASHER LOCATIONS (6L80)

Fig. 17: Bushing, Bearing and Washer Locations