Shift Linkage, Internal and External

Tools Required:

• Slide Hammer T50T-100-A
• Puller T58L-101-B
• Shift Shaft Seal Replacer T74P-44598-A
• Grommet Remover T84P-7341-A
• Grommet Replacer T84P-7341-B

Removal

1. It may be necessary to remove the fan shroud bolts and move the shroud away from the fan on models that require lowering the transmission for access to the manual lever.

2. Raise vehicle on a hoist so that transmission oil pan is accessible. Refer to Section 00-02.

3. Remove any interfering exhaust system components.

4. On vehicles that require additional clearance to remove the manual lever, lower the transmission.

5. Apply penetrating oil to the outer throttle lever retaining nut to prevent breaking the inner throttle lever.

6. Grasp the outer throttle lever and hold firmly. Remove the outer throttle lever retaining nut and lockwasher. Swing lever and TV rod or cable assembly out of the way for clearance.

7. Carefully disconnect the manual cable from the transmission manual lever at the transmission using the Grommet Remover Tool T84P-7341-A. For tool usage instructions, refer to Section 07-05.

8. Place a drain pan under the transmission oil pan. Starting at the rear of the pan and working toward the front, loosen the retaining bolts and allow the fluid to drain. Remove all of the retaining bolts except two at the front to allow the fluid to further drain. It may be necessary to use a 3/8-inch or 1/4-inch drive ratchet with a 10mm universal socket to remove the oil pan bolts. After all fluid has drained, remove the two remaining bolts and the oil pan and gasket. Discard the gasket. If the same fluid is to be used again, filter the fluid through a 100 mesh screen. Reuse the fluid only if it is in good condition.

9. Remove the transmission oil filter grommet and gasket. Discard the gasket. If the fluid is contaminated, discard the filter. (Do not clean the filter).

10. Remove the manual lever detent spring and roller assembly.

11. Remove the manual lever retaining pin by prying with a narrow sharp screwdriver. Use care when removing the pin not to damage machined surfaces.

12. Note assembled position of the TV lever torsion spring, then remove spring.

13. Slide a 5/8-inch box end wrench over the inner manual lever close to the bottom of the lever. Do not allow the wrench to contact the "rooster comb" area. Using a 21mm wrench, remove the manual lever retaining nut. Securely hold the inner manual lever with the box end wrench while applying break torque to the manual lever retaining nut. Do not allow "rooster comb" to rest against the machined surface.

14. Remove the outer manual lever from the case.

15. Remove inner throttle lever and shaft assembly.

16. Remove the inner manual lever and park pawl actuating rod assembly.

17. Disconnect the park pawl actuating rod from the inner manual lever.

18. Remove the manual lever oil seal with a screwdriver or Puller T58L-101-B and Impact Slide Hammer T50T-100-A. Discard the seal.

Installation

1. Install a new manual lever seal into the case using Shift Shaft Seal Replacer T74P-77498-A or equivalent.

2. Check the manual lever, shaft and threads for damage.

3. With the manual lever retaining nut on the inner throttle lever and shaft assembly, slide the inner throttle lever through the inner manual lever.

4. Slide the outer manual lever in the case. Make sure the lever is properly positioned either up or down depending on application.

5. Allow the inner throttle lever and shaft assembly to slide through the ID bore of the outer manual lever.

6. Snug up the manual lever retaining nut against the inner manual lever making sure the flats are properly aligned. Tighten the nut to remove free play, then tighten the nut to 26-37 Nm (20-27 lb-ft).

7. Position TV lever torsion spring on the inner throttle valve shaft and align into notch.

8. Push manual lever all the way into the case. Make sure inner manual lever pin is engaged in manual valve detent slot and inner throttle lever is acting on the TV valve. Neutral start switch plunger must also be riding on cam surface of inner manual lever.

9. Install new manual lever retaining pin in case. Pin must be flush or slightly below pan surface.

10. Install a new throttle lever seal.

11. Install detent spring. Ensure the detent spring roller is centered on "rooster comb" area. Tighten retaining bolt to 9-14 Nm (80-123 lb-in).

12. Install the throttle valve outer lever. Do not push inner throttle valve lever past throttle valve.

13. Install throttle lever lockwasher and retaining nut. Tighten nut to 8-13.5 Nm (71-119 lb-in).

14. Check PARK function and operation of TV lever and manual lever before further assembly.

15. Connect the manual linkage cable to the manual lever at the transmission using the Grommet Replacer T84P-7341-B. For tool usage instructions, refer to Section 07-05

16. Install the oil filter gasket and oil filter. Tighten retaining bolts to 9-14 Nm (80-123 lb-in).

17. Install oil pan with a new gasket and tighten retaining bolts to 8-13.5 Nm (71-119 lb-in). It might be necessary to use a 3/8-inch or 1/4-inch drive ratchet with a 10mm universal socket to install the oil pan bolts. On some vehicles it is easier to install the oil pan after the crossmember is installed.

18. Install exhaust system components and crossmember as appropriate. Install the fan shroud bolts, if removed.

19. Lower vehicle and fill transmission to the proper level with Synthetic MERCON® Multi-Purpose Automatic Transmission Fluid E6AZ-19582-B (ESR-M2C163-A2) or equivalent.

20. Check and adjust manual linkage. Refer to Section 07-05.

21. Start vehicle in PARK and with brake pedal applied, cycle gear selector several times. Recheck oil level. Check for leaks.

22. Check/adjust the TV linkage at the throttle body as outlined.