Opel Insignia Owners & Service Manuals

Opel Insignia: Repair Instructions - Off Vehicle

Torque Converter Assembly Removal

Automatic Transmission

  1. Torque Converter

TORQUE CONVERTER FLUID SEAL REMOVAL

Automatic Transmission

  1. Torque Converter Fluid Seal

Special Tools

EN-45000 Seal Remover

Equivalent regional tools: Refer to Special Tools

TRANSMISSION CONTROL MODULE REMOVAL

Automatic Transmission

  1. Transmission Control Module Bolt [3x]
  2. Transmission Control Module

TRANSMISSION FLUID FILLER OVERFLOW TUBE AND DRAIN PLUG REMOVAL

Automatic Transmission

  1. Transmission Oil Drain Plug
  2. Transmission Oil Drain Plug Seal

NOTE: Remove and DISCARD the seal.

  1. Transmission Oil Level Check Plug Seal
  2. Transmission Fluid Filler Upper Tube
  3. Transmission Oil Level Check Plug Seal

NOTE: Remove and DISCARD the seal.

CONTROL VALVE BODY COVER REMOVAL

Automatic Transmission

  1. Control Valve Body Cover Bolt [13x]
  2. Control Valve Body Cover

Procedure

Carefully slide the DT-37228 seal cutter around the perimeter of the control valve body cover to break the RTV seal.

Special Tools

DT-37228 Seal Cutter

For equivalent regional tools, refer to Special Tools.

WIRING HARNESS REMOVAL

Automatic Transmission

  1. Automatic Transmission Fluid Temperature Sensor Bolt
  2. Automatic Transmission Fluid Temperature Sensor Clip
  3. Automatic Transmission Wiring Harness Retainer
  4. Wiring Harness Wire

NOTE: Ensure you mark where each connector goes prior to removal.

  1. Automatic Transmission Wiring Connector Seal
  2. Automatic Transmission Wiring Connector Seal

CONTROL VALVE BODY ASSEMBLY REMOVAL

Automatic Transmission

  1. Valve Body Bolt[2x] M6 x 31
  2. Valve Body Bolt [1x] M6 x 51
  3. Valve Body Bolt[5x] M6 x 21
  4. Manual Valve Link

NOTE: Disconnect the manual valve link, DO NOT remove.

  1. Control Valve Body - Model Dependent

NOTE: For models with start/stop, Electronic Component Description.

INPUT SPEED SENSOR REMOVAL

Automatic Transmission

  1. Automatic Transmission Input Speed Sensor Bolt
  2. Automatic Transmission Input Speed Sensor

TORQUE CONVERTER AND DIFFERENTIAL HOUSING REMOVAL

Automatic Transmission

  1. Torque Converter Housing Bolt[5x] M8 x 30
  2. Torque Converter Housing Bolt[2x] M8 x 35
  3. Torque Converter Housing Bolt [2x] M10 x 40
  4. Torque Converter Housing Bolt[14x] M8 x 39
  5. Torque Converter and Differential Housing

DIFFERENTIAL ASSEMBLY REMOVAL

Automatic Transmission

  1. Differential

AUTOMATIC TRANSMISSION FLUID PUMP AND FLUID FILTER REMOVAL

Automatic Transmission

  1. Automatic Transmission Fluid Pump Bolt [2x]
  2. Automatic Transmission Fluid Pump Bolt [5x]
  3. Automatic Transmission Fluid Pump
  4. Automatic Transmission Fluid Filter Bolt [2x]
  5. Automatic Transmission Fluid Filter

NOTE: Remove and DISCARD the filter.

  1. Automatic Transmission Fluid Pump Seal[3x]

NOTE: Remove and DISCARD the seal.

  1. Automatic Transmission Fluid Pump Shaft Thrust Washer
  2. Automatic Transmission Fluid Pump Ring[4x]

NOTE: Remove and DISCARD the seal.

  1. Automatic Transmission Fluid Pump Seal

NOTE: Remove and DISCARD the seal.

FORWARD BAND SERVO PISTON REMOVAL

Automatic Transmission

  1. 2-4 Band Servo Cover Retaining Ring

WARNING: Before removing the spring, cover the spring with a towel to prevent the spring from flying and possibly causing damage or personal injury.

NOTE: Remove and DISCARD the retainer.

  1. 2-4 Band Servo Cover Seal - O-Ring

NOTE: Remove and DISCARD the seal.

  1. Forward Band Servo Cover
  2. Forward Clutch Accumulator Piston Fluid Seal Ring

NOTE: Remove and DISCARD the seal.

  1. Forward Band Servo Piston
  2. 2nd Clutch Accumulator Piston Spring

3RD CLUTCH AND FRONT CARRIER REMOVAL

Automatic Transmission

  1. Automatic Transmission Case Bolt

NOTE: 3rd Clutch Band may be removed without removing automatic transmission case bolt.

  1. 3rd Clutch
  2. Automatic Transmission Fluid Pump Shaft Thrust Washer
  3. Front Sun Gear
  4. Front Sun Gear Thrust Bearing Race
  5. Sun Gear Thrust Bearing
  6. Front Carrier Thrust Bearing Race
  7. Front Carrier
  8. Front Carrier Thrust Bearing Race
  9. Input Shaft Fluid Seal Ring[4x]

NOTE: Install NEW seals. Do NOT reuse old seals.

FRONT INTERNAL GEAR REMOVAL

Automatic Transmission

  1. Front Carrier Thrust Bearing
  2. Front Internal Gear
  3. Forward Clutch Backing Plate Retaining Ring
  4. Input Carrier Flange

FORWARD CLUTCH ASSEMBLY REMOVAL

Automatic Transmission

  1. Input Clutch Housing Thrust Bearing
  2. Forward Clutch Housing Thrust Bearing Race
  3. Forward Clutch

INPUT DRUM REMOVAL

Automatic Transmission

  1. Input Sun Gear Thrust Bearing
  2. Sun Gear Front Thrust Bearing Race
  3. Input Drum

Manual Shift Detent Lever and Park Pawl Removal

Park Components Removal

Automatic Transmission

Park Components Removal

  1. Manual Shift Detent Bolt
  2. Automatic Transmission Control Lever Detent Spring
  3. Manual Shift Detent Lever Spring
  4. Park Pawl Lockout Pin
  5. Park Pawl Shaft
  6. Park Pawl Spring
  7. Park Pawl
  8. Park Pawl Actuator Bracket Bolt
  9. Park Pawl Pin Spring Guide Sleeve
  10. Park Pawl Actuator Lever Spring
  11. Park Pawl Actuator Bracket Bolt
  12. Park Pawl Actuator Bracket
  13. Park Pawl Actuator Rod
  14. Manual Shift Shaft Lever

Lubricant Fluid Pipe Removal

Automatic Transmission

  1. Front Differential Transfer Drive Gear Fluid Passage Tube Bolt[2x]
  2. Automatic Transmission Control Wiring Harness Clamp
  3. Lubricant Fluid Pipe Retainer
  4. Lubricant Fluid Pipe
  5. Torque Converter and Differential Housing Bolt
  6. Automatic Transmission Vent Baffle Cover
  7. Torque Converter and Differential Housing Bolt
  8. Automatic Transmission Vent Baffle Cover

FINAL DRIVE PINION AND RING GEAR REMOVAL

Automatic Transmission

  1. Final Drive Pinion and Ring Gear

COUNTER DRIVE GEAR REMOVAL

Automatic Transmission

  1. Front Differential Transfer Drive Gear Fluid Passage Tube Bolt
  2. Automatic Transmission Control Wiring Harness Clamp

NOTE: It may be necessary to remove the automatic transmission control wiring harness clamp to access all the bolts.

  1. Center Support Bolt [6x]
  2. Counter Drive Gear
  3. Automatic Transmission Intermediate Speed Sensor Bolt
  4. Vehicle Speed Sensor
  5. Vehicle Speed Sensor Spacer

OVERRUN CLUTCH AND REAR CARRIER REMOVAL

Automatic Transmission

  1. Sun Gear
  2. Overrun Clutch Retaining Ring
  3. Overrun Clutch
  4. Rear Carrier Thrust Washer
  5. Rear Carrier
  6. Rear Carrier Thrust Washer

1ST AND REVERSE CLUTCH BACKING PLATE REMOVAL

Automatic Transmission

  1. 1-Reverse Clutch Backing Plate Retaining Ring
  2. Forward Clutch Backing Plate
  3. 1st and Reverse Clutch Plate - Friction Plate
  4. 1st and Reverse Clutch Plate
  5. 1st and Reverse Clutch Backing Plate

DIRECT CLUTCH ASSEMBLY REMOVAL

Automatic Transmission

  1. Rear Sun Gear Thrust Bearing
  2. Rear Sun Gear Thrust Bearing Race
  3. Rear Sun Gear
  4. Rear Sun Gear Thrust Bearing Race
  5. Direct Clutch Bearing
  6. Direct Clutch Hub Thrust Bearing Race
  7. Direct Clutch

LOW AND REVERSE CLUTCH PISTON REMOVAL

Automatic Transmission

  1. 1-Reverse Clutch Spring Retaining Ring
  2. 1-Reverse Clutch Spring
  3. Low and Reverse Clutch Piston

Procedure

Apply compressed air to the case passage to remove the low and reverse clutch piston.

  1. Low and Reverse Clutch Application Ring
  2. Low and Reverse Clutch Application Ring
  3. 2nd Clutch Housing Rear Bearing
  4. Direct Clutch Hub Thrust Bearing Race
  5. Direct Clutch Fluid Seal Ring [2x]

MANUAL SHIFT SHAFT SEAL REMOVAL

Automatic Transmission

  1. Manual Shift Shaft Seal
    Special Tools
    DT-43911 Selector Shaft Seal Remover
    For equivalent regional tools, refer to Special Tools.

FRONT WHEEL DRIVE SHAFT OIL SEAL REMOVAL - RIGHT SIDE

Automatic Transmission

  1. Front Wheel Drive Shaft Oil Seal - Right Side

Special Tools

  • DT-26941 Remover
  • GE-6125-1B Slide Hammer with Adapter

For equivalent regional tools, refer to Special Tools.

DIFFERENTIAL BEARING RACE REMOVAL

Automatic Transmission

  1. Differential Bearing Race

Special Tools

  • DT-45124 Removal Bridge
  • DT-45124-9 Puller Leg
  • DT-51919 Bearing Race Remover

Equivalent regional tools: Refer to Special Tools.

COUNTER GEAR THRUST BEARING RACE REMOVAL

Automatic Transmission

  1. Counter Gear Thrust Bearing Race

Special Tools

  • DT-45124 Removal Bridge
  • DT-45124-9 Puller Leg
  • DT-51919 Bearing Race Remover

Equivalent regional tools: Refer to Special Tools

COUNTER GEAR THRUST BEARING RACE INSTALLATION

Automatic Transmission

  1. Counter Gear Thrust Bearing Race

Special Tools

  • DT-51918 Bearing Race Installer
  • GE-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

DIFFERENTIAL BEARING RACE INSTALLATION

Automatic Transmission

  1. Differential Bearing Race

Special Tools

  • DT-51918 Bearing Race Installer
  • GE-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

FRONT WHEEL DRIVE SHAFT OIL SEAL INSTALLATION - RIGHT SIDE

Automatic Transmission

  1. Front Wheel Drive Shaft Oil Seal - Right Side

Special Tools

  • DT-50298 Axle Seal Installer
  • GE-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

MANUAL SHIFT SHAFT SEAL INSTALLATION

Automatic Transmission

  1. Manual Shift Shaft Seal
    Special Tools
    DT-49101 Seal Installer
    For equivalent regional tools, refer to Special Tools.

Low and Reverse Clutch Piston Installation

Automatic Transmission

  1. Direct Clutch Fluid Seal Ring [2x]
  2. Direct Clutch Hub Thrust Bearing Race
  3. 2nd Clutch Housing Rear Bearing
  4. Low and Reverse Clutch Application Ring
  5. Low and Reverse Clutch Application Ring
  6. Low and Reverse Clutch Piston
  7. 1-Reverse Clutch Spring
  8. 1-Reverse Clutch Spring Retaining Ring

Procedure

Using the DT-48056 bridge with DT-48903 and DT-51920 compressors, install the retaining ring.

NOTE: Ensure DT-51920 Clutch Spring Compressor is clocked properly and only making contact with the 1-Reverse clutch spring.

Special Tools

  • DT-48056 Spring Compressor Bridge
  • DT-48903 Spring Compressor
  • DT-51920 Clutch Spring Compressor

Equivalent regional tools: Refer to Special Tools

DIRECT CLUTCH ASSEMBLY INSTALLATION

Automatic Transmission

  1. Direct Clutch
  2. Direct Clutch Hub Thrust Bearing Race
  3. Direct Clutch Bearing
  4. Rear Sun Gear Thrust Bearing Race
  5. Rear Sun Gear
  6. Rear Sun Gear Thrust Bearing Race
  7. Rear Sun Gear Thrust Bearing

REAR CARRIER INSTALLATION

Automatic Transmission

  1. Rear Carrier Thrust Washer
  2. Rear Carrier

Procedure

  1. Assemble this on the table with Direct Clutch Assembly Installation.
  2. Rotate till seated completely.
  3. Install complete direct clutch and rear carrier assembly as a unit.
  1. Rear Carrier Thrust Washer
  2. Sun Gear

1ST AND REVERSE CLUTCH BACKING PLATE INSTALLATION

Automatic Transmission

  1. 1st and Reverse Clutch Backing Plate

NOTE: Machined side down.

  1. 1st and Reverse Clutch Plate
  2. 1st and Reverse Clutch Plate - Friction Plate
  3. Forward Clutch Backing Plate

NOTE: Groove up to accept the retaining ring.

  1. 1-Reverse Clutch Backing Plate Retaining Ring

OVERRUN CLUTCH INSTALLATION

Automatic Transmission

  1. Overrun Clutch

NOTE: Rotate the rear carrier clockwise while installing.

  1. Overrun Clutch Retaining Ring

NOTE: Rotate the rear carrier clockwise until fully seated to accept retaining ring.

COUNTER DRIVE GEAR INSTALLATION

Automatic Transmission
Fig. 3: Automatic Transmission Counter Drive Gear Bolts Tightening Sequence

  1. Vehicle Speed Sensor Spacer
  2. Vehicle Speed Sensor
  3. Automatic Transmission Intermediate Speed Sensor Bolt

CAUTION: Refer to Fastener Caution.

Tighten 5 N.m (44 lb in)

  1. Counter Drive Gear
  2. Center Support Bolt[6x]

Tighten in sequence 62 N.m (46 lb ft)

  1. Automatic Transmission Control Wiring Harness Clamp
  2. Front Differential Transfer Drive Gear Fluid Passage Tube Bolt

Tighten 7 N.m (62 lb in)

FINAL DRIVE PINION AND RING GEAR INSTALLATION

Automatic Transmission

  1. Final Drive Pinion and Ring Gear

MANUAL SHIFT DETENT LEVER AND PARK PAWL INSTALLATION

Lubricant Fluid Pipe Installation

Automatic Transmission

  1. Automatic Transmission Vent Baffle Cover
  2. Torque Converter and Differential Housing Bolt

CAUTION: Refer to Fastener Caution.

Tighten 7 N.m (62 lb in)

  1. Automatic Transmission Vent Baffle Cover
  2. Torque Converter and Differential Housing Bolt

Tighten 7 N.m (62 lb in)

  1. Lubricant Fluid Pipe
  2. Lubricant Fluid Pipe Retainer
  3. Automatic Transmission Control Wiring Harness Clamp
  4. Front Differential Transfer Drive Gear Fluid Passage Tube Bolt [2x]

Tighten 7 N.m (62 lb in)

Park Components Installation

Automatic Transmission

  1. Manual Shift Shaft Lever
  2. Park Pawl Actuator Rod

NOTE: Rotate the manual shift shaft lever to get rod in place.

  1. Park Pawl
  2. Park Pawl Spring

NOTE: Ensure spring is in proper location like the inset shows.

  1. Park Pawl Shaft
  2. Park Pawl Lockout Pin
  3. Park Pawl Actuator Bracket

NOTE: Ensure park pawl actuator rod is in proper location like the inset shows before tightening the bolts.

  1. Park Pawl Actuator Bracket Bolt

CAUTION: Refer to Fastener Caution.

Tighten 9 N.m (80 lb in)

  1. Park Pawl Pin Spring Guide Sleeve
  2. Park Pawl Actuator Lever Spring

NOTE: Ensure Spring is in proper location like the inset shows.

  1. Park Pawl Actuator Bracket Bolt

Tighten 9 N.m (80 lb in)

  1. Manual Shift Detent Lever Spring
  2. Automatic Transmission Control Lever Detent Spring
  3. Manual Shift Detent Bolt

Tighten 10 N.m (89 lb in)

INPUT DRUM INSTALLATION

Automatic Transmission

  1. Input Drum
  2. Sun Gear Front Thrust Bearing Race
  3. Input Sun Gear Thrust Bearing

FORWARD CLUTCH ASSEMBLY INSTALLATION

Automatic Transmission

  1. Forward Clutch
  2. Forward Clutch Housing Thrust Bearing Race
  3. Input Clutch Housing Thrust Bearing

Front Internal Gear Installation

Automatic Transmission

  1. Input Carrier Flange
  2. Forward Clutch Backing Plate Retaining Ring
  3. Front Internal Gear

NOTE: Rotate to index the clutch plate and ensure seated.

  1. Front Carrier Thrust Bearing
  2. Front Carrier Thrust Bearing Race

FRONT CARRIER INSTALLATION

Automatic Transmission

  1. Sun Gear Rear Thrust Bearing Race
  2. Front Carrier
  3. Input Shaft Fluid Seal Ring[4x]

NOTE: Remove and DISCARD the seal.

  1. Front Carrier Thrust Bearing Race
  2. Sun Gear Thrust Bearing
  3. Front Sun Gear

NOTE: Groove side up.

  1. Automatic Transmission Fluid Pump Shaft Thrust Washer

3RD CLUTCH INSTALLATION

Automatic Transmission

  1. 3rd Clutch

NOTE: Line up the fiber plates to help seat, will have to rotate and rock to get to fully seat in place.

  1. Automatic Transmission Case Bolt (Band Anchor)

CAUTION: Refer to Fastener Caution.

Tighten 167 N.m (123 lb ft)

FORWARD BAND SERVO PISTON INSTALLATION

Automatic Transmission

  1. 2nd Clutch Accumulator Piston Spring
  2. Forward Band Servo Piston

NOTE: Pin on the servo piston needs to index on the band.

  1. Forward Clutch Accumulator Piston Fluid Seal Ring

NOTE: Install a NEW seal. Do NOT reuse the old seal.

  1. Forward Band Servo Cover
  2. 2-4 Band Servo Cover Seal (O-ring)

NOTE: Install a NEW seal. Do NOT reuse the old seal.

  1. 2-4 Band Servo Cover Retaining Ring

NOTE: Install a NEW retaining ring.

AUTOMATIC TRANSMISSION FLUID PUMP AND FLUID FILTER INSTALLATION

Automatic Transmission

  1. Automatic Transmission Fluid Pump Ring[4x]

NOTE: Install NEW seals. Do NOT reuse old seals.

  1. Automatic Transmission Fluid Pump Shaft Thrust Washer
  2. Automatic Transmission Fluid Filter

NOTE: Install a NEW filter. DO NOT reuse old filter.

  1. Automatic Transmission Fluid Filter Bolt [2x]

CAUTION: Refer to Fastener Caution.

Tighten 5 N.m (44 lb in)

  1. Automatic Transmission Fluid Pump

NOTE: Ensure the 3 black seals are on the fluid pump.

  1. Automatic Transmission Fluid Pump Seal

NOTE: Install a NEW seal. Do NOT reuse the old seal.

  1. Automatic Transmission Fluid Pump Bolt [5x]

Tighten 25 N.m (18 lb ft)

  1. Automatic Transmission Fluid Pump Bolt [2x]

Tighten 25 N.m (18 lb ft)

  1. Automatic Transmission Fluid Pump Seal[3x]

NOTE: Install NEW seals. Do NOT reuse old seals.

DIFFERENTIAL ASSEMBLY INSTALLATION

Automatic Transmission

  1. Differential

TORQUE CONVERTER AND DIFFERENTIAL HOUSING ASSEMBLY DISASSEMBLE

Automatic Transmission

  1. Automatic Transmission Fluid Baffle Bolt [2x]
  2. Automatic Transmission Fluid Baffle
  3. Automatic Transmission Fluid Baffle Bolt
  4. Lubricant Fluid Hose Clamp
  5. Front Differential Transfer Drive Gear Fluid Passage Tube

FRONT WHEEL DRIVE SHAFT OIL SEAL REMOVAL - LEFT SIDE

Automatic Transmission

  1. Front Wheel Drive Shaft Oil Seal - Left Side

    Special Tools

    • DT-26941 Remover
    • GE-6125-1B Slide Hammer with Adapter

    For equivalent regional tools, refer to Special Tools.

DIFFERENTIAL DRIVE PINION GEAR OUTER BEARING RACE REMOVAL

Automatic Transmission

  1. Differential Drive Pinion Gear Outer Bearing Race

Special Tools

  • DT-45124 Removal Bridge
  • DT-45124-9 Puller Leg
  • DT-51919 Bearing Race Remover

Equivalent regional tools: Refer to Special Tools

DIFFERENTIAL CARRIER BEARING RACE REMOVAL

Automatic Transmission

  1. Differential Carrier Bearing Race

Special Tools

  • DT-45124 Removal Bridge
  • DT-45124-9 Puller Leg
  • DT-51919 Bearing Race Remover

Equivalent regional tools: Refer to Special Tools

DIFFERENTIAL CARRIER BEARING RACE INSTALLATION

Automatic Transmission

  1. Differential Carrier Bearing Race

Special Tools

  • DT-51918 Bearing Race Installer
  • GE-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

DIFFERENTIAL DRIVE PINION GEAR OUTER BEARING RACE INSTALLATION

Automatic Transmission

  1. Differential Drive Pinion Gear Outer Bearing Race

    Special Tools

    • DT-51918 Bearing Race Installer
    • GE-8092 Driver Handle

    For equivalent regional tools, refer to Special Tools.

FRONT WHEEL DRIVE SHAFT OIL SEAL INSTALLATION - LEFT SIDE

Automatic Transmission

  1. Front Wheel Drive Shaft Oil Seal - Left Side

Special Tools

  • DT-52512 Axle Seal Installer
  • GE-8092 Driver Handle

For equivalent regional tools, refer to Special Tools.

Torque Converter and Differential Housing Assembly Assemble

Automatic Transmission

  1. Front Differential Transfer Drive Gear Fluid Passage Tube
  2. Lubricant Fluid Hose Clamp
  3. Automatic Transmission Fluid Baffle Bolt

CAUTION: Refer to Fastener Caution.

Tighten 7 N.m (62 lb in)

  1. Automatic Transmission Fluid Baffle
  2. Automatic Transmission Fluid Baffle Bolt [2x]

Tighten 7 N.m (62 lb in)

TORQUE CONVERTER AND DIFFERENTIAL HOUSING INSTALLATION

Automatic Transmission
Fig. 4: Torque Converter And Differential Housing Bolts Tightening Sequence

  1. Torque Converter and Differential Housing

Procedure

Install a bead of sealant around the perimeter of the torque converter and differential housing mating surface: Refer to Adhesives, Fluids, Lubricants, and Sealers.

  1. Torque Converter Housing Bolt[2x] M10 x 40

CAUTION: Refer to Fastener Caution.

Tighten in sequence 35 N.m (26 lb ft)

  1. Torque Converter Housing Bolt[2x] M8 x 35

Tighten in sequence 29 N.m (21 lb ft)

  1. Torque Converter Housing Bolt[14x] M8 x 39

Tighten in sequence 29 N.m (21 lb ft)

  1. Torque Converter Housing Bolt [5x] M8 x 30

Tighten in sequence 29 N.m (21 lb ft)

INPUT SPEED SENSOR INSTALLATION

Automatic Transmission

  1. Automatic Transmission Input Speed Sensor
  2. Automatic Transmission Input Speed Sensor Bolt

CAUTION: Refer to Fastener Caution.

Tighten 5 N.m (44 lb in)

CONTROL VALVE BODY ASSEMBLY INSTALLATION

Automatic Transmission

  1. Control Valve Body - Model Dependent

NOTE: For models with start/stop, Electronic Component Description.

  1. Valve Body Bolt [5x] M6 x 21

CAUTION: Refer to Fastener Caution.

Tighten 10 N.m (89 lb in)

  1. Valve Body Bolt[1x] M6 x 51

Tighten 10 N.m (89 lb in)

  1. Valve Body Bolt[2x] M6 x 31

Tighten 10 N.m (89 lb in)

  1. Manual Valve Link

NOTE: Ensure you reconnect the manual valve link.

WIRING HARNESS INSTALLATION

Automatic Transmission

  1. Automatic Transmission Wiring Connector Seal
  2. Automatic Transmission Wiring Connector Seal
  3. Wiring Harness Wire

NOTE: Tab on wiring harness connector fits in slot on case to insure alignment of transmission control module (TCM).

  1. Automatic Transmission Wiring Harness Retainer
  2. Automatic Transmission Fluid Temperature Sensor Clip
  3. Automatic Transmission Fluid Temperature Sensor Bolt

Procedure

Connect the wiring harness connectors to the control valve body in proper location as mark when removed.

Tighten 7 N.m (62 lb in)

CONTROL VALVE BODY COVER INSTALLATION

Automatic Transmission
Fig. 5: Automatic Transmission Valve Body Control Unit Cover Bolts Tightening Sequence

  1. Control Valve Body Cover

Procedure

Install a bead of sealant around the perimeter of the case to valve body cover mating surface: Refer to Adhesives, Fluids, Lubricants, and Sealers.

  1. Control Valve Body Cover Bolt [13x]

CAUTION: Refer to Fastener Caution.

Tighten in sequence 13 N.m (115 lb in)

TRANSMISSION FLUID FILLER OVERFLOW TUBE AND DRAIN PLUG INSTALLATION

Automatic Transmission

  1. Transmission Oil Level Check Plug Seal

NOTE: Install a NEW seal. Do NOT reuse the old seal.

  1. Transmission Fluid Filler Upper Tube
  2. Transmission Oil Level Check Plug Seal

CAUTION: Refer to Fastener Caution.

Tighten 47N.m (35 lb ft)

  1. Transmission Oil Drain Plug Seal

NOTE: Install a NEW seal. Do NOT reuse the old seal.

  1. Transmission Oil Drain Plug

Tighten 7N.m (62 lb in)

TRANSMISSION CONTROL MODULE INSTALLATION

Automatic Transmission

  1. Transmission Control Module
  2. Transmission Control Module Bolt [3x]

CAUTION: Refer to Fastener Caution.

Tighten 25N.m (18 lb ft)

TORQUE CONVERTER FLUID SEAL INSTALLATION

Automatic Transmission

  1. Torque Converter Fluid Seal

Procedure

Install seal with hand, then finish by tapping around perimeter with rubber mallet until properly seated.

NOTE: Install a NEW seal. Do NOT reuse the old seal.

TORQUE CONVERTER ASSEMBLY INSTALLATION

Automatic Transmission

  1. Torque Converter

    READ NEXT:

     Description and Operation

    Transmission Identification Information For automatic transmission AF50, the identification plate is on the top of the transmission housing. Aisin Warner transmission type Fabrication line 1 = 00

     Special Tools and Equipment

    SPECIAL TOOLS DT-26941 J-26941 Remover DT-37228 J-37228 Seal Cutter DT-43911 J-43911 Selector Shaft Seal Remover DT-44215 J-44215 Rear Seal Installer DT-44809 J-44809 Output Shaft Seal Installer

     Power Transfer Unit/Transfer Case - AAM

    SEE MORE:

     Repair Instructions

    PROPELLER SHAFT REPLACEMENT Special Tools DT-51329 Drive Shaft Remover GE-2619-A Slide Hammer Equivalent regional tools:Special Tools. Removal Procedure 1. Raise and support the vehicle. 2. Floor Panel Tunnel Panel Front Brace(3) - Remove. 3. Floor Panel Tunnel Panel Rear Brace(2) - Remove. 4

     Specifications, Schematic and Routing Diagrams

    SPECIFICATIONS TEMPERATURE VERSUS RESISTANCE FASTENER SPECIFICATIONS (2.0L LTG) Single Use Non-Threaded Fasteners/Components NOTE: All fasteners/components listed in this table MUST BE DISCARDED and replaced with NEW after removal. Reusable Threaded Fastener Tightening Specifications NOTE: All f

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