GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 1998 🢒 Sun Runner - 4WD (Canada) 🢒 Engine 🢒 Engine Controls - 1.6L 🢒 Torque Converter Clutch Solenoid Replacement

Removal Procedure

    Object Number: 167899 Size: SH

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable (4).
  2. Raise the vehicle. Support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    3. Object Number: 166185 Size: SH
  3. Place an index mark (reference mark) (1) on the propeller shaft pinion flange.
  4. Place and index mark (reference mark) on the front differential pinion flange of the transfer case to front differential propeller shaft (four-wheel drive models).
  5. Remove the four nuts and bolts from the front differential pinion flange (four-wheel drive models).

    6. Important: Removing the propeller shaft from the transfer case will result in fluid loss (four-wheel drive models).

  6. Separate the pinion flange yoke from the front differential pinion flange (four-wheel drive models).
  7. Position and support the transfer case to the front differential propeller shaft away from the transmission fluid pan.

    8. Object Number: 166191 Size: SH
  8. Place a drain pan or suitable container under the transmission drain plug (1).
  9. Remove the drain plug in order to allow the transmission fluid pan (2) to drain.
  10. Remove the fourteen transmission fluid pan (2) bolts from the transmission.
  11. Remove the transmission fluid pan from the transmission.
  12. Remove the gasket from the transmission.

    13. Object Number: 203313 Size: SH
  13. Remove the three fluid pipes in the following order: 7, 4 and 8.

    14. Object Number: 166630 Size: SH
  14. Remove the electrical connector from the Torque Converter Clutch (TCC) solenoid.
  15. Remove the two bolts from the lower valve body.

    16. Object Number: 153876 Size: SH
  16. Remove the TCC solenoid (1) from the lower valve body.
  17. Inspect the TCC solenoid pipe O-ring (2) for cuts and other damage. Replace the O-ring as necessary.
  18. For TCC solenoid inspection and diagnosis procedures, refer to Transmission Diagnosis Driveability Emissions. For a complete schematic of the TCC system, refer to Automatic Transmission Controls Schematics .

Installation Procedure

    Object Number: 153873 Size: SH
  1. Install the new Torque Converter Clutch (TCC) solenoid gasket and TCC Solenoid (1) onto the lower valve body.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Secure the TCC solenoid (1) onto the lower valve body with the two bolts.

    3. Tighten
    Tighten the TCC solenoid bolts to 5 N·m (44 lb in).

  3. Install the electrical connector to the TCC solenoid.

    4. Object Number: 203313 Size: SH
  4. Apply a thin coat of automatic transmission fluid to the fluid pipe O-rings.
  5. Install the fluid pipes in the following order 8, 4 and 7.

    6. Object Number: 166191 Size: SH

    Important: When installing the transmission pan, ensure that the filler tube connects properly.

  6. Install the new transmission fluid pan gasket and transmission fluid pan (2) to the transmission.
  7. Secure the transmission fluid pan (2) to the transmission with the fourteen bolts.

    8. Tighten
    Tighten the fluid pan bolts to 5 N·m (44 lb in).

  8. Install the transmission drain plug (1) into the transmission.

    9. Tighten
    Tighten the transmission drain plug to 16 N·m (12 lb ft).

  9. Install the front propeller shaft into the vehicle aligning the index marks made during the front propeller shaft removal. Secure the shaft with four bolts and four nuts (four-wheel drive models).

    10. Tighten
    Tighten the front propeller shaft bolts and nuts to 50 N·m (37 lb ft).

  10. Lower the vehicle.
  11. Connect the negative (-) battery cable.
  12. Refill the transmission as necessary using the following procedure.
    13. 12.1. Place the vehicle on a level surface
    12.2. Remove the fluid level indicator
    12.3. Add approximately 1.5 liters (1.6 qts) or Dexron®-III automatic transmission fluid GM P/N 12346143, or the equivalent, into the fluid filler tube.
    12.4. Install the fluid level indicator into the fluid filler tube.
    12.5. Apply the parking brake and block the vehicle wheels.
    12.6. With the selector lever in the PARK position, start the engine. Do not race the engine.
    12.7. Run the engine at idle and move the selector lever through each range and return to the PARK position.
    12.8. With the engine running at idle, remove the fluid level indicator from the filler tube and wipe the indicator off.
    12.9. Reinsert the fluid level indicator into the filler tube making sure it is seated in its original position.
    12.10. Remove the indicator and check the fluid level. The level should be between the FULL HOT and LOW HOT marks. If the level is below the LOW HOT mark, add fluid to bring the level to the FULL HOT mark. Bringing the fluid level from the LOW HOT mark to the FULL HOT mark requires 0.3 liters (0.3 qts) of fluid. Use Dexron®-III automatic transmission fluid GM P/N 12346143, or the equivalent.
    12.11. Conduct a road test and check the transmission level. Refer to Transmission Fluid Check .