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Makes 🢒 Chevrolet 🢒 2002 🢒 Chevrolet W-Series Commercial WT (WT5500) 🢒 Bulletins 🢒 Info - Approved Aisin Automatic Transmission On-Vehicle Repairs

Info - Approved Aisin Automatic Transmission On-Vehicle Repairs

Subject:Approved Aisin Automatic Transmission On-Vehicle Repairs

Models:1999-2004 Chevrolet W-Series Medium Duty Tilt Cab Models
1999-2004 GMC W-Series Medium Duty Tilt Cab Models
1999-2004 Isuzu NPR/NQR Commercial Medium Duty Models
with 4HE1-T Diesel Engine and Aisin Automatic Transmission


In response to requests from the field and in an effort to reduce repair costs of the Aisin transmission, the following On-Vehicle services have been approved for service at the dealer level.

The following procedures have been approved for repair. Refer to the Automatic Transmission sub-section of the 1999-2001NPR/NQR W3500/W4500/W5500 Service Manual-Chassis for the correct repair procedures.

Approved Procedure

Service Manual Page

ATF Temperature Switch R&R

7A3-10

ATF Thermo Sensor R&R

7A4-102

Lock Up Solenoid R&R

7A3-14

Inhibitor Switch R&R

7A3-6

Timing Solenoid R&R

7A3-14

Shift Solenoid 1 R&R

7A3-14

Shift Solenoid 2 R&R

7A3-14

Speedo Drive Gear R&R

See attached procedure

Pan Gasket R&R

7A3-12

Rear Cover Oil Seal R&R

7A3-15

Speedo Drive Gear R&R Procedure
  1. Block the wheels.
  2. Disconnect the negative battery cable.
  3. Reference mark the flange yoke to the parking drum and remove the propeller shaft.
  4. Raise the stake of the lock nut and remove the lock nut. Apply the parking brake or place in Park in order to keep the output shaft from moving.
  5. Remove the output shaft O-ring.
  6. Remove the brake drum.
  7. Remove the drive coupling from the output shaft.
  8. Remove the parking brake assembly.
  9. Remove the extension housing fasteners (qty of 10) and remove the housing. Be sure to have a drain pan beneath the transmission. Removal of the housing may cause some fluid to leak out.
  10. Remove the drive gear spacer and gear from the output shaft.
  11. Install a new speedometer drive gear and spacer.
  12. Place a new gasket on the transmission case.
  13. Install the parking lock rod between the parking lock pawl and the bracket and attach the extension housing on the transmission case.
  14. Apply sealant to the thread of the two bolts indicated on page 7A4-90 of the Service Manual. Install the two bolts as indicated in the Service Manual.
  15. Install the remaining eight housing bolts.

    16. Tighten
    Tighten the bolts to 37 N·m (27 lb ft).

  16. Install vehicle speed sensor 1.

    17. Tighten
    Tighten the bolt to 8 N·m (69 lb in).

  17. Install the parking brake assembly.

    18. Tighten
    Tighten the parking brake bolts to 83 N·m (61 lb ft).

    Notice: Do NOT damage the oil seal.

  18. Install the drive coupling to the output shaft.
  19. Install the parking brake drum. Set the parking brake or select "P" range in order to prevent the output shaft from turning.
  20. Install a new O-ring and new coupling nut.

    21. Tighten
    Tighten the nut to 170 N·m (125 lb ft).

  21. Stake the nut with a chisel.
  22. Line up the reference marks and install the propeller shaft to the driver coupling.

    23. Tighten
    Tighten to 102 N·m (75 lb ft).

  23. Connect the negative battery cable.
  24. Remove the wheel blocks.

Parts Information

The following parts information is provided to assist in any repairs.

For Chevrolet and GMC Models:

 

P/N

Description

Model Year

97202035

Switch, Temp

99-Current

97202071

Seal, A/Trans Case Extn

99-Current

97202072

Qty of 2

Solenoid, No.1 or No.2 Shft

99-Current

97202073

Solenoid, Lock Up

99-Current

97202074

Solenoid, Timing

99-Current

97202076

Switch, Park/Neu Posn

1999-2000 Only

97202077

Sensor, Spd Input/Output

1999-2000 Only

97202082

Nut, A/T Coupling Driver

99-Current

97202087

Gasket, Coupling Driver

99-Current

97229529

Sensor, Spd Input/Output

2001-Current

97229531

Switch, Park/Neu Posn

2001-Current

97256858

Gear, Speedo Drv

99-Current

97257141

Solenoid, Trans Kickdown Shft

99-Current

97257142

Sensor, TCC Temp

2001-Current

97728534

Seal, Trans Oil Pan

99-Current

Parts are currently available from GMSPO.

For Isuzu Models:

 

P/N

Description

Application

8-97202-035-0

Switch, Temp

99-Current

8-97202-071-0

Seal, A/Trans Case Extn

99-Current

8-97202-072-0

Qty of 2

Solenoid, No.1 or No.2 Shft

99-Current

8-97202-073-0

Solenoid, Lock Up

99-Current

8-97202-074-0

Solenoid, Timing

99-Current

8-97202-076-0

Switch, Park/Neu Posn

1999-2000 Only

8-97202-077-0

Sensor, Spd Input/Output

1999-2000 Only

8-97202-082-0

Nut, A/T Coupling Driver

99-Current

8-97202-087-0

Gasket, Coupling Driver

99-Current

8-97229-529-0

Sensor, Spd Input/Output

2001- Current

8-97229-531-0

Switch, Park/Neu Posn

2001-Current

8-97256-858-0

Gear, Speedo Drv

99-Current

8-97256-870-0

Gasket, Ext. Housing

99-Current

8-97257-141-0

Solenoid, Trans Kickdown Shft

99-Current

8-97257-142-0

Sensor, TCC Temp

2001-Current

2-90067-700-0

Seal, Trans Oil Pan

99-Current

Parts are to be obtained from AIPDN.

Warranty Information

The following new labor operation information is provided for warranty claim submission.

Labor Operation

Description

Labor Time

K6275

Transmission Inhibitor Switch - Replace

0.4 hr

K6533

Add

Solenoid / Transmission Kick-down Shift - Replace

For replacement of each additional solenoid

0.6 hr

0.1 hr

K6306

Sensor, TCC Temperature - Replace

0.6 hr

K6364

Sensor, Spd Input/Output - Replace

0.3 hr

K6480

Auto Transmission Fluid Thermo Switch - Replace

0.3 hr

K6320

Speedo Gear - Replace

1.3 hrs

K6360

RR Extension HSG Seal - Replace

1.2 hrs

K6500

Transmission Oil Gasket - Replace

0.5 hr