Note. It is not necessary to remove the automatic transmission from the vehicle to remove and install the valve body.
Removing
Attention.
- A hot gearbox and automatic transmission fluid can cause various burns. Switch off the engine and wait until the gearbox has cooled down.
- When compressed air is supplied, various contaminants and particles fly out, which can get into the eyes. Wear protective goggles when working with compressed air.
- If the transmission valve body is replaced with a new one, an initial learning procedure must be performed (see section later in this chapter).
- If you place the valve body with the connector side down on a flat surface, the valve body connector or sensors may be damaged. To service the valve body, place it on a soft material that does not emit dust and other foreign particles! Make sure that the valve body connector and sensors do not touch the bench surface directly.
1. Move the selector lever to position P.
2. Disconnect the negative battery terminal.
3. Remove the front protective tray #2.
4. Thoroughly clean the outside of the gearbox with steam or cleaning agents.
5. Remove the engine air filter assembly.
6. Disconnect the valve body connector.
Attention.
- Be careful not to touch the terminals of the connector with your hands, as this may damage the terminals.
- Water or foreign objects entering the connector can cause poor connections and corrosion. When disconnecting the connector, make sure that water and foreign objects do not get into it.
7. Remove the hose clamp.
8. Drain the automatic transmission fluid.
9. Remove the automatic transmission oil pan.
Attention. To prevent damage to the valve body, if a large amount of sediment is found in the oil pan when removing the transmission oil pan, replace the oil pickup with a new one. If there is no sediment in the gearbox oil pan, the oil pickup does not need to be replaced.
Note. Be sure to use new mounting bolts when re-oiling the pan.
10. Remove the oil pickup.
11. Remove the O-rings from the oil pickup.
12. Remove the valve body.
Attention. Remove the valve body directly from below so that no force is applied to the valve body connector in the transverse direction.
13. Remove the valve body seal.
14. Remove the gaskets from the gearbox housing.
Installation
1. Install new gaskets in the gearbox housing.
Note: replace the part with a new one after each removal.
2. Insert dowel pins into valve body.
Note. If the dowel pin remains in the transmission case, remove it and insert it into the valve body.
3. Gearboxes GW6A-EL, GW6AX-EL:
Prepare a plastic plate of the dimensions indicated in the figure.
A: 20 mm. B: ∅ 8 mm. C: 15 mm. D: 65 mm.
Note. Use a plastic plate of not too hard material.
Insert the valve coil with the spring into the gearbox housing and fix the bypass valve with the spring using the plastic plate prepared earlier, as shown in the figure.
4. Install the valve body so that the auxiliary parking lever engages the gap between the two surfaces of the spool portion of the manual valve. Tighten the mounting bolts to 9-10 Nm.
Attention. Install the valve body so that the turbine/mainshaft speed sensor, output shaft speed sensor, and valve body connector do not touch the transmission case.
Gearboxes GW6A-EL, GW6AAX-EL
Attention. Because the valve body can be damaged due to foreign material, the plastic plate must be carefully removed to prevent the valve body from getting in.
5. By moving the manual valve to both sides (according to the arrow in the figure), make sure the manual valve is properly connected to the auxiliary park lever and mode sensor sliding pin.
Note. If the hand valve only moves in the gap between the auxiliary park lever and the surface of the manual valve, the manual valve and the auxiliary park lever are properly connected.
6. Install the oil pickup O-ring.
Note. If there is a large amount of sediment in the gearbox oil pan, replace the oil pickup with a new one.
Note: replace the part with a new one after each removal.
7. Install the oil intake and tighten the mounting bolts to a torque of 9-10 Nm.
8. Apply a thin layer of silicone sealant (TV1217E) on the contact surfaces of the oil pan and gearbox housing.
Attention. Remove residual silicone sealant from the contact surfaces of the gearbox housing and oil pan and degrease the sealing surfaces. Otherwise, leaks may occur.
9. Install the oil pan and tighten the new mounting bolts to 8-10 Nm before the sealant begins to harden.
10. Install the #2 front skid plate.
11. Install the valve body seal.
12. Install a new hose clamp in the position shown in the figure.
Attention.
- Reusing a hose clamp can cause automatic transmission fluid leaks, so only a new hose clamp should be used.
- Install the lugs of the hose clamp so that they are in the range A shown in the figure.
Note: replace the part with a new one after each removal.
Attention. Install the hose clamp so that it does not snag on the top and bottom edges of the stuffing box to ensure proper tightness.
13. Connect the valve body connector.
Attention.
- Be careful not to touch the terminals of the connector with your hands, as this may damage the terminals.
- Water or foreign objects entering the connector can cause poor connections and corrosion. When disconnecting the connector, make sure that water and foreign objects do not get into it.
- Insert the connector straight so as not to damage its pins.
- Turn the connector lever until it clicks.
14. Fill with automatic transmission fluid.
15. Install the engine air filter assembly.
16. Connect the negative battery terminal.
17. In case of valve body replacement, perform transmission control module configuration and initial learning procedures (see relevant section of this chapter).
18. Check the mechanical part of the gearbox (see relevant section earlier in this chapter).
19. Road test the automatic transmission (see relevant section earlier in this chapter).