Automatic Transaxle Overhaul & Testing - 4t65-e Buick Century VI

APPLICATION

TRANSAXLE APPLICATION

Transaxle has a metal identification plate or Service Replacement Transmission Assembly (SRTA) plate attached to rear face of transaxle. (Scheme 1) Transaxle RPO codes are MN3, MN7, M15 or M76. The MN3 and MN7 are heavy duty models and have 10.2" (258 mm) torque converters. The M15 model has a 9.6" (245 mm) torque converter. The M76 model is used in All Wheel Drive (AWD) applications. For model build information on each RPO code (Scheme 2)- (Scheme 9).

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

GEAR RATIOS

TRANSAXLE GEAR RATIOS

DESCRIPTION & OPERATION

Hydra-Matic 4T65-E is a fully automatic front wheel drive electronically controlled transaxle. Four forward ranges including overdrive are provided. Powertrain Control Module (PCM) controls shift points using two shift solenoids. A vane-type oil pump supplies oil pressure. PCM regulates oil pressure using pressure control solenoid valve. All vehicles equipped with 4T65-E transaxle have an Electronically Controlled Capacity Clutch (ECCC) system. In ECCC system, pressure plate does not fully lock to torque converter cover. It is precisely controlled to maintain a small amount of slippage between engine and turbine, reducing driveline torsional disturbances.

Multiplied torque from torque converter is transferred to transaxle by a sprocket and drive chain (drive link) assembly. Other internal components consist of 4 multiple-disc clutches, roller clutch, sprag clutch, 3 bands and compound planetary gear set. Final drive gear and differential assemblies are an integral part of transaxle. (Scheme 14)- (Scheme 20).

Note. Drive chain may also be referred to as "drive link".

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

LUBRICATION

Note. See appropriate SERVICING - A/T article.

TROUBLE SHOOTING

Note. Transaxle malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of hydraulic, mechanical or electronic components. Ensure all concerns have been properly checked prior to transaxle overhaul. See appropriate DIAGNOSIS article.

Visual Inspection

Inspect and replace torque converter for the following conditions

1. Overheated (torque converter will be blue in color).
2. ATF leaking at weld areas.
3. Damaged torque converter pilot.
4. Evidence of metal particles in torque converter, oil cooler, or cooler pipes.
5. Damaged torque converter stator, damaged pump, or damaged turbine.
6. Damaged or worn torque converter bushing.
7. Contaminated ATF due to engine coolant.

Inspect torque converter for stripped bolt hole threads. Repair as necessary.

Stator Check

With torque converter removed from vehicle, stator roller clutch can be checked by inserting 2 fingers into splined inner race of roller clutch and attempting to rotate race in both directions. Inner race should rotate freely clockwise, but should not rotate or should be difficult to rotate counterclockwise.

End Play Check

Mount Torque Converter End Play Fixture (J-35138) and Dial Indicator (J-8001) on torque converter to check end play. End play should be 0-.020" (0-.50 mm). (Scheme 21)

Scheme 21

TORQUE CONVERTER

Remove torque converter and turbine shaft "O" ring seal. (Scheme 22) Install Holding Fixture (J-28664-B) onto transaxle. (Scheme 23) Install transaxle and holding fixture into Base (J-3289-20). Insert pin into base to hold transaxle in desired position.

Scheme 22

Scheme 23

TRANSFER CASE REMOVAL

1. Remove output shaft snap ring. (Scheme 24) Rotate transaxle 90 degrees. Remove transfer case lower brace bolt. (Scheme 25) Rotate transaxle 90 degrees.
2. Remove transfer case side brace. (Scheme 26) Remove transfer case-to-transaxle bolts. (Scheme 27)
3. Remove transfer case assembly from transaxle. (Scheme 28) Remove transfer case lower brace. (Scheme 29) Remove case extension seal from transfer case. (Scheme 30)
4. Position transaxle with case side cover facing down. Remove oil dam from transaxle. (Scheme 31) Install transfer case assembly onto Holding Fixture (J 44755). (Scheme 32)
5. Using Slide Hammer (J-6125-1B) and Adapter (J-44467), remove output shaft. (Scheme 33) Remove final drive sun gear. (Scheme 34)
6. Remove sun gear thrust washer from transaxle. (Scheme 35) Remove parking gear and thrust bearing. (Scheme 36) Remove final drive sun gear shaft. (Scheme 37)

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

REVERSE BAND SERVO

1. Using long screwdriver, depress reverse band servo cover by prying against holding fixture. Pry retaining ring from reverse band servo cover. (Scheme 38)
2. Remove screwdriver. Servo assembly will push servo cover up. Using small screwdriver, pull servo cover "O" ring seal out through slot in case. Cut servo "O" ring seal. Depress reverse band servo cover. Grasp one end of cut seal and pull from servo cover. Servo assembly will push servo cover up. Remove servo cover, reverse band servo assembly and reverse band servo piston return spring. (Scheme 39)

Scheme 38

Scheme 39

FORWARD BAND SERVO

Position transaxle with oil pan facing up. Using long screwdriver, depress forward band servo assembly cover by prying against work bench. Hold servo assembly and remove forward band servo cover bolts. (Scheme 40) Remove screwdriver. Servo assembly will push servo cover out. If cover does not move, tap cover with mallet. Remove servo cover and cover seal. Remove servo assembly. Remove piston return spring from forward band servo. (Scheme 41)

Scheme 40

Scheme 41

OIL PAN & FILTER

Remove oil pan bolts. Remove oil pan and gasket. Using screwdriver, pry oil filter out of case. Pry oil filter seal out of case. DO NOT damage case sealing surface. (Scheme 16) Inspect oil pan magnet for steel particles. Excessive amounts of steel shavings indicates internal transaxle damage. Using screwdriver, pry metal crimping away from top of oil filter and pull oil filter apart. Inspect oil filter for clutch plate friction material, steel particles and Bronze slivers, indicating bushing damage or internal transaxle damage.

ACCUMULATOR ASSEMBLY & 2-1 MANUAL BAND SERVO

1. Remove accumulator cover bolts from 1-2 and 2-3 accumulator cover. (Scheme 42) Remove bolts from 2-1 manual band servo cover. Using screwdriver, gently pry lube oil pipe retainer from case. (Scheme 43) Remove lube oil pipe from front differential carrier internal gear lube hole. (Scheme 44)
2. Remove 1-2 and 2-3 accumulator assembly and 2-1 manual band servo assembly together. Remove pipe assembly. DO NOT twist pipe assembly. Remove cover gasket from 2-1 manual band servo.

Scheme 42

Scheme 43

Scheme 44

CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR

1. Position transaxle with control valve body cover facing up. Remove case side cover (control valve body cover) bolts. (Scheme 45) Remove cover and gaskets. (Scheme 15) Using small screwdriver, pry wiring harness electrical connectors off transaxle fluid pressure manual valve position switch, 1-2 and 3-4 shift solenoid, 2-3 shift solenoid, TCC PWM solenoid, pressure control solenoid and input speed sensor. Gently pull transaxle fluid temperature sensor from clip. (Scheme 46)and (Scheme 47).
2. Lift wiring harness assembly off transaxle. Remove oil pump assembly bolts. DO NOT remove No. 1 oil pump cover bolt at this time. (Scheme 48) Remove wiring harness clip. Lift oil pump assembly off control valve body. (Scheme 49) Set oil pump assembly on its cover.
3. Remove control valve body bolts. (Scheme 50) Manual valve position switch is very delicate, use care when handling. Carefully lift manual valve position switch off control valve body. (Scheme 51) Remove control valve body. (Scheme 52) Remove 4 check balls from case cover. (Scheme 53) Remove 2 bolts retaining spacer plate and gaskets to valve body. Remove spacer plate with 2 screen/seal assemblies and gaskets from valve body. Remove 6 check balls from valve body. (Scheme 54) Remove case cover pin.
4. Remove oil pump drive shaft from case cover. (Scheme 55) Position transaxle so Vehicle Speed Sensor (VSS) is facing up. Remove VSS bolt and VSS. (Scheme 16)

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

OUTPUT SHAFT

1. Remove case extension bolts. Remove case extension and extension seal. (Scheme 56) Leave front differential carrier thrust washer and bearing on carrier. Rotate differential carrier until differential carrier pinion shaft is in horizontal position.
2. Place Axle Remover Wedge (J 42562) between end of output shaft and differential pinion shaft. Using hammer, strike axle removal wedge to compress snap ring and push output shaft from differential side gear. (Scheme 57) Remove differential carrier assembly and snap ring from output shaft. (Scheme 58) Remove output shaft assembly. (Scheme 59)

Scheme 56

Scheme 57

Scheme 58

Scheme 59

FRONT DIFFERENTIAL CARRIER END PLAY CHECK

1. Ensure thrust washer and bearing are on front differential carrier. Install case extension seal onto case extension, if removed. Install case extension onto transaxle. (Scheme 56) Install 2 case extension bolts. DO NOT tighten bolts to specification. Only tighten bolts until case extension is fully seated.
2. Position transaxle with case extension facing up. Install Aligning Tool (J-26958) and dial indicator. (Scheme 60) Zero dial indicator. Use Snap Ring Remover (J-28585) or large screwdriver to lift front differential carrier. Pry up on VSS reluctor wheel through sensor hole in case extension.
3. Note dial indicator measurement. End play should be.005-.025" (.13-.64 mm). Record measurement for reassembly reference. If dial indicator reading is less than.005" (.13 mm), install next smaller size thrust washer, and check end play. If dial indicator reading is more than.025" (.64 mm), install next larger size thrust washer, and check end play. For available thrust washer sizes, see «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table under TRANSAXLE REASSEMBLY.

Scheme 60

MANUAL VALVE LINK & OIL DAM

1. Remove manual shift detent bolt and manual shift detent. (Scheme 61) Compress manual valve link spring. Lift link off manual valve. (Scheme 62)
2. Position manual valve so valve will not interfere with case cover removal. Remove oil dam from case. (Scheme 63) Using small screwdriver, pry input speed sensor clip out of case cover. Use care when handling speed sensor. Carefully pull input speed sensor out of case cover. (Scheme 64)

Scheme 61

Scheme 62

Scheme 63

Scheme 64

CASE COVER & GASKETS

Remove indicated case cover bolts. (Scheme 65) Hold manual valve in place. Lift case cover and thrust washers off case. (Scheme 66) Remove upper and lower case cover gaskets. (Scheme 67)

Scheme 65

Scheme 66

Scheme 67

4TH CLUTCH SHAFT & PLATES

Remove 4th clutch backing plate, composition plates and steel plates. Remove 4th clutch shaft. Remove drive link lube scoop. (Scheme 68)

Scheme 68

Drive Chain (Drive Link) Stretch Check

Ensure driven sprocket support assembly and both sprockets are fully seated. Pull drive link toward case at indicated location. (Scheme 69) Measure distance between case and drive link. If measurement is.126" (3.2 mm) or more, drive link may be reused. If measurement is less than.126" (3.2 mm), replace drive link.

Drive & Driven Sprocket Disassembly

1. Remove 4th clutch shaft thrust washer. Remove drive sprocket thrust washer. Washer may be stuck to case cover. Remove VSS reluctor wheel. Note location of drive link assembly master link. Master link is different color than other links and may be facing up or down toward case.
2. Lift drive and driven sprockets with drive link out of case. Lift both sides evenly. It may be necessary to tap turbine shaft up gently with a rubber mallet. Remove drive and driven sprocket thrust washers. (Scheme 70) Thrust washers may be stuck to sprockets.

Scheme 69

Scheme 70

DRIVEN SPROCKET SUPPORT ASSEMBLY

Insert 2 case cover bolts into driven sprocket support assembly. (Scheme 71) Grasp bolts and lift support assembly. Remove thrust washer from 2nd clutch housing. Washer may be stuck to support assembly.

Scheme 71

INPUT & 2ND CLUTCH ASSEMBLIES

1. Adjust collar on Final Drive/Clutch Remover/Installer (J-33381-A) to ensure threaded rod is fully loosened. Install Remover/Installer into 2nd clutch housing assembly. Tighten threaded rod until rod is finger tight. Lift up on remover/installer with 2nd clutch and input clutch assemblies attached. Sprag clutch assemblies will also be attached. (Scheme 72)
2. Place complete assembly on bench. Loosen threaded rod and remove remover/installer. Lift 2nd clutch housing assembly off input clutch housing. Remove input clutch housing thrust bearing from input housing. Remove selective thrust washer from input clutch housing. (Scheme 73)

Scheme 72

Scheme 73

REVERSE BAND & REACTION DRUM

Tilt band to disengage band from anchor pin in case. Remove reverse band. (Scheme 74) Lift reverse reaction drum from transaxle case. (Scheme 75)

Scheme 74

Scheme 75

All Wheel Drive

1. Install final drive sun gear shaft. (Scheme 37) Use petroleum jelly to retain parking gear thrust bearing to parking gear. Install parking gear thrust bearing and parking gear. (Scheme 36) Install final drive sun gear. (Scheme 34)
2. Install End Play Checking Tool (J-44472). (Scheme 76) Install bolts and tighten securely to prevent tool deflection during end play measurement.
3. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer to lift input clutch housing. (Scheme 72) Install input clutch housing assembly into case. Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input clutch housing.
4. Using 2 bolts, install End Play Gauge (J-33386) onto case. (Scheme 77) Tighten bolts to securely hold end play gauge. Tighten end play checking tool finger tight to eliminate differential carrier end play.
5. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge, measure end play between end play gauge and thrust washer.
6. Record measurement for proper end play clearance during reassembly. End play should be 0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during transaxle reassembly. If end play is greater than.006" (.15 mm), select next size larger thrust washer and recheck. For input clutch thrust washer identification, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table under TRANSAXLE REASSEMBLY.
7. Remove end play checking tool. (Scheme 76) Install remover/installer into input clutch housing. Tighten threaded rod of remover/installer until rod is finger tight. Using remover/installer, lift input clutch housing assembly (sprag clutch assemblies will also be attached) from case.
8. Position transaxle so oil pan is facing down. Remove final drive sun gear, parking gear, parking gear thrust bearing and final drive sun gear shaft.

Except All Wheel Drive

1. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer to lift input clutch housing. (Scheme 72) Install input clutch housing assembly into case. Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input clutch housing.
2. Remove remover/installer from input clutch housing. Install case extension with Output Shaft Loading/Aligning Tool (J-26958), Adapter Plug (J-26958-10) and Loading Tool Adapter (J-43425) attached to case extension. (Scheme 78) Using 2 bolts, install End Play Gauge (J-33386) onto case. (Scheme 77) Tighten bolts to securely hold gauge. Tighten aligning tool finger tight in order to eliminate differential carrier end play. (Scheme 78)
3. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge, measure end play between end play gauge and thrust washer.
4. Record measurement for proper end play clearance during reassembly. End play should be 0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during transaxle reassembly. If end play is greater than.006" (.15 mm), select next size larger thrust washer and recheck. For input clutch thrust washer identification, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table under TRANSAXLE REASSEMBLY.
5. Remove end play gauge. Install remover/installer into input clutch housing. Lift input clutch housing from case. Remove aligning tool, adapter plug and loading tool adapter from case extension.

Scheme 76

Scheme 77

Scheme 78

CASE EXTENSION & DIFFERENTIAL CARRIER

Remove case extension bolts. Remove case extension and remove seal. Remove differential carrier thrust washer and thrust bearing. (Scheme 56) Remove differential carrier assembly. Remove differential sun gear shaft. Remove thrust bearing from differential carrier sun gear. Bearing may be stuck to carrier assembly. Remove differential carrier (final drive) sun gear. Remove parking gear. Remove thrust bearing from differential carrier internal gear. (Scheme 79)

Scheme 79

INPUT & REACTION CARRIER

Position transaxle with case cover facing up. Remove input carrier assembly. (Scheme 80) Remove input carrier and reaction carrier lube dam. (Scheme 81) Lube dam may be stuck to input carrier assembly. Remove thrust bearing from reaction carrier. Remove reaction carrier assembly.

Scheme 80

Scheme 81

REACTION SUN GEAR & 2-1 MANUAL BAND

Remove thrust bearing from reaction sun gear. Remove reaction sun gear assembly. (Scheme 82) Tilt band to disengage 2-1 manual band assembly from anchor pin. Remove 2-1 manual band from case. (Scheme 83)

Scheme 82

Scheme 83

1-2 SUPPORT DRUM & FORWARD BAND

Install Support Remover/Installer (J-38358) onto 1-2 support drum assembly. Lift remover/installer with 1-2 support drum out of case. (Scheme 84) Tilt band to disengage band from anchor pin. Remove forward band from case. (Scheme 85)

Scheme 84

Scheme 85

FINAL DRIVE INTERNAL GEAR

Remove thrust washer from final drive internal gear. Use snap ring remover or large screwdriver to remove final drive internal gear retaining ring. Lift final drive internal gear out of case by depressing parking pawl to clear case. (Scheme 86)

Scheme 86

PARKING SYSTEM COMPONENTS

1. Using side cutting pliers, remove manual shift shaft pin. DO NOT cut through pin. Protect case with piece of wood or rubber under pliers when removing pin. (Scheme 87) Remove manual valve link and spring from manual shift detent lever. Remove manual shift detent lever nut from manual shift shaft. Remove manual shift detent lever and remove parking pawl actuator. (Scheme 88)
2. Position transaxle with reverse band servo bore facing up. Pull manual shift shaft out of case. Using small screwdriver, pry manual shift shaft seal from case. Remove parking pawl actuator guide pin. Remove parking pawl actuator guide from case. Remove actuator guide seal from guide. (Scheme 89)

Scheme 87

Scheme 88

Scheme 89

Inspection

1. Inspect components still on transaxle case for the following: Loose, cross-threaded, or damaged ATF cooler pipe fittings. Loose, missing, or damaged transaxle name plate. Loose, plugged, or damaged vent assembly. Loose, cross-threaded, or damaged oil pressure test hole plug.
2. Inspect transaxle case for the following: Damaged or porous gasket sealing surfaces. Stripped or damaged bolt or screw holes (repair with thread insert). Damaged or porous case oil passages. Damaged snap ring grooves or housing splines. Loose, missing, or damaged band anchor pins. Damaged or porous case surfaces. Plugged drain back holes for torque converter oil seal.

Disassembly & Reassembly

If vent is damaged, use pliers and pry bar to remove vent. (Scheme 90) Use hammer and punch to install vent. If oil pressure test hole plug was removed, install plug and tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 90

Inspect drive sprocket support for the following

1. Damaged splines.
2. Damaged drive sprocket support bearing.
3. Damaged turbine shaft bushing (pressed inside support).

Remove drive sprocket support bearing and/or drive sprocket support assembly only if damaged.

Using slide hammer and Universal Seal Remover (J-23129), remove torque converter seal. (Scheme 91) If damage is visible to drive sprocket support bearing, use slide hammer and Bushing/Bearing Remover (J-26941) to remove bearing from drive sprocket support. (Scheme 92) Remove drive sprocket support bolts and remove drive sprocket. (Scheme 93) Install NEW bearing using drive handle and bearing installer. (Scheme 92) Install drive sprocket support. Install and tighten drive sprocket support bolts to specification. See TORQUE SPECIFICATIONS. Using Seal Installer (J-28540) and mallet, install NEW torque converter seal.

Scheme 91

Scheme 92

Scheme 93

Inspection & Reassembly

1. Inspect park system components for the following: Worn park pawl actuator guide. Damaged or bent park pawl actuator assembly. Damaged manual shift shaft detent lever or IMS detent lever. Worn, stripped, or bent manual shift shaft. Bent or damaged manual valve link. Kinked or bent manual valve link spring. Replace components as necessary. (Scheme 94)
2. Install NEW shift shaft seal into case using 9/16" socket and hammer. (Scheme 95) Install NEW parking pawl actuator guide "O" ring seal onto parking pawl actuator guide. Install actuator guide into case. Align slot for actuator guide pin in parking pawl with pin hole in case. Install actuator guide pin using mallet. (Scheme 89)
3. Install manual shift shaft detent lever onto manual shift shaft. Install nut on shift shaft and tighten to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications). Install detent lever onto parking pawl actuator. Install manual shift shaft detent lever assembly and parking pawl actuator assembly into case. (Scheme 96)
4. Align groove for manual shift shaft pin with pin hole in case. Install manual shift shaft pin using mallet. (Scheme 97)

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Inspect differential carrier internal gear assembly for the following

1. Damaged or worn bushings.
2. Plugged lube oil holes.
3. Damaged case splines.
4. Damaged or worn gear teeth.
5. Damaged or worn park pawl assembly.
6. Damaged snap ring.

Replace components as necessary. (Scheme 98)

Scheme 98

Disassembly

1. Using feeler gauge, measure differential carrier planetary pinion gear end play. End play should be.009-.025" (.23-.64 mm). (Scheme 99) If end play is not as specified, repair differential carrier assembly as necessary.
2. Using screwdriver remove retaining ring from front differential carrier. (Scheme 100) Remove planetary pinion gear pin, thrust washers, roller bearings, spacer and pinion gear. (Scheme 101) Remove remaining planetary pinions in same manner. Remove differential carrier sun gear thrust bearing.
3. Place final drive carrier components into oil pan to ensure roller bearings are not lost. Using drift pin and hammer remove differential pinion shaft retaining pin. (Scheme 102) Remove differential pinion gear shaft, gears, pinion gear thrust washers, side gears and side gear thrust washers. (Scheme 103)

1. Inspect differential carrier assembly for the following: Damaged or worn teeth, bearing rollers, washers, or pins on differential planetary pinion gear. Damaged or worn teeth or splines on final drive sun gear. Damaged or worn teeth, splines, or thrust washers on differential side gear. Damaged or worn teeth, thrust washers, or shaft on differential pinion gear. Damaged or worn lugs or splines on parking gear. Damaged VSS reluctor wheel. Damaged internal gear/parking gear thrust bearing, differential carrier/sun gear thrust bearing or differential carrier/case thrust bearing. Damaged or worn differential carrier/case selective thrust washer. Damaged differential/final drive carrier housing. Replace components as necessary. (Scheme 56), (Scheme 101), (Scheme 103) and (Scheme 104). If VSS reluctor wheel is damaged, see «VEHICLE SPEED SENSOR RELUCTOR WHEEL»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__vehicle-speed-sensor-reluctor-wheel).
2. Inspect final drive sun gear shaft for the following: Damaged or worn splines. Cracks at lube oil holes. Damaged or worn bearing journals.

Reassembly

1. Assemble differential side gears and thrust washers into carrier. Using petroleum jelly, stick thrust washers onto pinion gears. Assemble pinion gears and thrust washers into differential carrier. (Scheme 103) Rotate gears into position. Slide differential pinion shaft into carrier through pinion gears. Align holes in pinion shaft retaining pin to hole in carrier housing. Using drift pin and hammer, install pinion shaft retaining pin into carrier. (Scheme 102)
2. Apply petroleum jelly to inside of differential carrier planetary pinion gear. For each planetary pinion gear, insert roller bearing spacer onto pin. Spacer must be inserted between 2 rows of roller bearings. Install roller bearings into gear one at a time. Differential ratio of 2.86:1 or 2.84:1 has 2 rows of 18 rollers. All other gear ratios have 2 rows of 22 rollers. (Scheme 105) Occasionally twist pinion gear pin to help align rollers.
3. Install differential carrier sun gear thrust bearing into carrier housing. (Scheme 101) Remove planetary pinion gear pin from its pinion gear. DO NOT move rollers out of position. Attach 2 pinion gear thrust washers on each side of pinion gear. Ensure position of pinion gears in housing is same as when disassembled. Install pinion gear assemblies into carrier housing. Install planetary pinion gear pins. Install retaining ring over planetary pinion gear pins. (Scheme 100)
4. Install final drive sun gear with chamfered side toward parking gear into carrier assembly. Install parking gear onto final drive sun gear shaft. Install final drive sun gear shaft/parking gear assembly into final drive sun gear. Apply petroleum jelly to parking gear side of parking gear thrust bearing and install onto parking gear. (Scheme 104)

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

VEHICLE SPEED SENSOR RELUCTOR WHEEL

Note. DO NOT remove reluctor wheel unless damaged.

To remove reluctor wheel, install flat metal stock over output shaft opening. Position Bearing Remover (J-22888) arms onto outer edges of reluctor wheel. Position bearing remover shaft onto flat metal stock. Pull wheel off of carrier. (Scheme 106) To reassemble, heat reluctor wheel slightly. Using plastic mallet, install reluctor wheel onto carrier by tapping evenly around reluctor wheel edge.

Scheme 106

Inspect case extension for the following

1. Damaged or porous sealing surface for case extension seal.
2. Damaged or porous sealing surface for VSS.
3. Damaged or porous sealing surface for right drive shaft oil seal.
4. Damaged bolt holes.
5. Worn or damaged front differential carrier bushing or output shaft bearing assembly.
6. Porous or damaged case extension housing.

Repair as necessary. (Scheme 107)

Scheme 107

1. Inspect forward band assembly for the following: Damaged or severely worn friction material. Damaged apply or anchor pin features.
2. Inspect differential carrier internal gear thrust washer for damage. Replace components as necessary. (Scheme 85)

Using small screwdriver, gently pry thrust bearing off of 1-2 support drum. Lift 1-2 support roller clutch assembly out of 1-2 support drum. (Scheme 108)

Inspect 1-2 support roller clutch components for the following

1. Scored or burned contact surface for manual 2-1 band on 1-2 support drum.
2. Damaged or worn forward drum bushing.
3. Damaged or worn inner race of 1-2 support roller clutch.
4. Damaged or worn 1-2 clutch roller assembly.
5. Damaged thrust bearing.

Replace components as necessary. (Scheme 109)

Install 1-2 roller clutch assembly into 1-2 support drum. Note position of cage assembly to inner race. (Scheme 110) Install thrust bearing onto 1-2 support drum. Press down with hand pressure only.

Functional Check

Position 1-2 support drum on bench. Install reaction sun gear assembly into 1-2 support drum. Rotate reaction sun gear counterclockwise. Rotate 1-2 support drum clockwise. (Scheme 111) Roller clutch should move freely in indicated directions. Roller clutch should lock in opposite direction. If roller clutch does not function as described, clutch is not assembled correctly. Reassemble as necessary.

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Inspect 2-1 manual band for cracked, separated or worn friction material. Inspect for cracks around apply lugs. Replace components as necessary. (Scheme 83)

Inspect reaction sun gear and drum for the following

1. Worn or scored bushings.
2. Damaged reaction sun gear teeth.
3. Band apply area of drum for discoloration or wear.
4. Welds connecting sun gear to drum for voids or cracks.
5. Worn or damaged 1-2 support outer race.

Replace components as necessary. (Scheme 112)

Scheme 112

1. Using feeler gauge, check for excessive pinion gear end play in input carrier and reaction carrier assemblies. End play should be.009-.030" (.23-.76 mm). If end play is not as specified, replace appropriate component. (Scheme 113)
2. Inspect thrust bearings, reaction carrier and input carrier for the following: Damaged cage. Damaged or missing rollers. Damage to pinion teeth. Damage to internal gear teeth. Damage to spline teeth. Replace components as necessary. (Scheme 114)

Scheme 113

Scheme 114

1. Inspect for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25-degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10-degree sides.
2. Inspect reverse reaction drum for cracks, damaged splines or distortion. (Scheme 75) Replace drum if necessary.

1. Remove input and 3rd sprag clutch assemblies from input clutch housing. (Scheme 115) Remove and discard spiral lock retaining ring from input clutch sprag outer race retainer. Remove 3rd clutch sprag assembly and input clutch sprag assembly from input and 3rd clutch sprag inner race. (Scheme 116) Remove input and 3rd clutch sprag inner race and input sun gear spacer from input sun gear.
2. Remove 3rd clutch sprag outer race retainer. Remove input and 3rd clutch sprag end bearings and input and 3rd clutch sprag center bearing from sprag outer races. Remove 3rd clutch and input clutch sprag assemblies from sprag outer races. (Scheme 117)

Inspect outer races for worn or damaged splines, scoring on inside diameter of races, wear or cracks. Inspect sprag components for flat spots. Inspect cage assemblies for distortion or broken ribbon tabs. Inspect end bearings and center bearing for cracks. Check input sun gear spacer for worn or damaged splines, or wear and cracks. Inspect input sun gear for worn or damaged splines or plugged lube holes or cracks. (Scheme 116)and (Scheme 117). Replace components as necessary.

1. Position input clutch sprag outer race on flat surface with flat side facing down. Insert end bearing with flat side down into input clutch sprag outer race. Insert input sprag into outer race. (Scheme 117)
2. Position 3rd clutch sprag outer race on flat surface with beveled side facing down. Install center bearing into 3rd clutch. Install 3rd sprag into 3rd clutch outer race. Lip on sprag cage must be facing up. Insert input and 3rd clutch sprag end bearing into third clutch sprag outer race with flat side up. (Scheme 117)
3. Install input clutch sprag assembly onto input and 3rd clutch sprag inner race with flat side of input clutch sprag outer race facing down. Install 3rd clutch sprag assembly onto input and 3rd clutch sprag inner race with beveled side of 3rd clutch sprag outer race facing input clutch sprag assembly. Install 3rd clutch sprag outer race retainer onto 3rd clutch sprag outer race. (Scheme 117)
4. Using small flat-blade screwdriver, install retaining ring onto input clutch sprag. Assemble spacer onto input sun gear. Install input and 3rd sprag clutch assemblies onto input sun gear. (Scheme 118)

Input Clutch & 3rd Sprag Clutch Functional Check

Hold input sun gear stationary. 3rd sprag clutch outer race should rotate only in counterclockwise direction and lock in clockwise direction. Input sprag clutch outer race should rotate in clockwise direction and lock in counterclockwise direction. (Scheme 119)

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove input clutch backing plate. Remove all input clutch plate assemblies. Remove input clutch waved plate and input clutch apply plate. (Scheme 120)
2. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove 3rd clutch backing plate. Remove 3rd clutch plate assembly. Remove 3rd clutch waved plate. (Scheme 121) Remove input shaft thrust bearing. (Scheme 122)
3. Using spring compressor and adapter, compress 3rd clutch spring assembly. Using snap ring pliers, remove retaining ring from input clutch housing. (Scheme 123) DO NOT over expand retaining ring during removal. Remove adapter, spring compressor and 3rd clutch spring assembly. Remove 3rd clutch piston and seal. (Scheme 124)
4. Using spring compressor, compress input clutch spring and retainer assembly. Using snap ring pliers, remove retaining ring from input clutch housing. (Scheme 125) DO NOT over expand retaining ring during removal. Remove spring compressor. Remove 3rd clutch piston housing, spring assembly and input clutch piston. (Scheme 126)
5. Remove 3rd clutch piston inner seal, 3rd clutch housing "O" ring seal and input clutch piston inner seal. Cut and remove input shaft oil seal rings. DO NOT damage grooves on shaft when oil seal ring is removed. (Scheme 127)

1. Inspect input clutch housing for the following: Plugged feed passages. Worn or damaged splines. Input shaft bushing wear. Seal ring groove nicks or burrs. Crack or blocked fluid passages in input shaft. Damage or wear to thrust bearing in input clutch housing. Replace components as necessary. (Scheme 128)
2. With check ball in seated position, add ATF to input clutch housing, and inspect for leaks. If check ball assembly leaks, see «INPUT CLUTCH HOUSING CHECK BALL VALVE»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__input-clutch-housing-check-ball-valve). Inspect input clutch piston for cracks or damage to seal grooves. Inspect for wear on piston lugs. Inspect input clutch and 3rd clutch spring assemblies for damaged cage or distorted or missing springs. DO NOT attempt to reuse 3rd clutch piston and seal. (Scheme 124)and (Scheme 126). Check input shaft thrust bearing for damage or wear. (Scheme 122) Replace components as necessary.

1. Lubricate NEW input clutch piston inner seal with ATF. Using Input Clutch Inner Piston Seal Protector (J-37361), install input clutch piston inner seal onto input clutch housing. (Scheme 129) Install NEW "O" ring seal in input clutch housing. (Scheme 130) Lubricate NEW 3rd clutch piston inner seal with ATF. Using Third Clutch Inner Piston Seal Protector (J-37362), install 3rd clutch piston inner seal onto input clutch housing. (Scheme 131)
2. Lubricate NEW input clutch piston outer seal with ATF, install seal onto piston. (Scheme 132) Install input clutch piston into input clutch housing. Install input clutch spring and retainer into input clutch housing. Install 3rd clutch piston housing into input clutch housing. (Scheme 126) Using spring compressor and snap ring pliers, install retaining ring in 3rd clutch housing. (Scheme 125) Remove spring compressor.
3. Lubricate NEW 3rd clutch piston assembly with ATF and install into input housing. Install 3rd clutch spring assembly into input housing. (Scheme 124) Using spring compressor, adapter and snap ring pliers, install 3rd clutch housing retaining ring. (Scheme 123)
4. Insert 3rd clutch waved plate into input housing. Install first external splined plate with steel side against waved plate. Place composition side of all plates facing up. Install 3rd clutch plates into input housing. Start by inserting a steel 3rd clutch plate with external splines. Alternate with internal splined plates. Install 3rd clutch backing plate with UP marking facing up. Install retaining ring into input housing. (Scheme 121)
5. Install input clutch apply plate into input housing with notched side of teeth facing downward against retaining ring on 3rd clutch backing plate. Install input clutch waved plate. Install input clutch plates starting with an input clutch steel plate and alternating with input clutch composition plate. Install input clutch backing plate with tapered teeth side facing up. Install retaining ring on input clutch housing. (Scheme 120) Install input shaft thrust bearing into input clutch housing. (Scheme 122)

Input Clutch & 3rd Clutch Functional Check

Using rubber tipped air nozzle, apply a maximum of 20 psi (1.4 kg/cm 2 ) air pressure at indicated fluid passage holes. (Scheme 133) Ensure input clutch and 3rd clutch apply. If clutch does not apply, recheck component reassembly.

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

INPUT CLUTCH HOUSING CHECK BALL VALVE

Note. Remove check ball valve only if inspection or leak check indicates problem with check ball valve.

Using 1/4" drift and hammer, remove check ball valve from input clutch housing. To reassemble, use 3/8" drift and hammer to install check ball valve into input clutch housing. (Scheme 134)

Scheme 134

Input Shaft Oil Seal Ring Replacement

1. Remove solid oil seal rings from input shaft. Inspect seal ring grooves for nicks or burrs. Lubricate each oil seal ring, and position individually onto Seal Protector (J-34741-1). (Scheme 135)
2. Quickly slide each seal into ring groove when protector is in position. Using Seal Driver (J-34741-2), push ring over seal protector. Size seal with Seal Sizer (J-34741-3). Gently twist seal sizer over each seal. Leave sizer in place until input clutch housing installation.

Scheme 135

Using small screwdriver, align teeth of input clutch plate assembly with 3rd clutch plate assembly. Ensure sprag assembly is fully seated into housing. Insert combined input sprag clutch and 3rd sprag clutch assembly into input clutch housing assembly. (Scheme 115)

Using flat-blade screwdriver, remove retaining ring from 2nd clutch housing. Remove backing plate, composition plates, steel plates, apply plate and waved plate. (Scheme 136) Using spring compressor, compress 2nd clutch piston spring. Remove retaining ring. (Scheme 137) Remove 2nd clutch spring assembly and 2nd clutch piston. (Scheme 138)

1. Inspect 2nd clutch housing for the following: Leaking or damaged ball check valve. Turn housing to seat check ball. Using ATF, check for leaking or damaged check ball valve in 2nd clutch housing. If check ball assembly leaks, replace check ball assembly. See «2ND CLUTCH HOUSING CHECK BALL VALVE»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e). Scored or worn bushings. Discolored band surface or wear on drum caused by excess heat. Flatness of band surface on drum. Damaged reverse reaction drum splines. Cracks in welds. Replace components as necessary. (Scheme 139)
2. Check for damaged reverse reaction drum splines. (Scheme 75) Original 2nd clutch and reverse reaction drums have splines with 25-degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10-degree sides. Check for cracks in welds. Inspect backing plate and waved plate for cracks and heat spots. Inspect steel and composition plates for wear, lining separation, pitting, flaking or damage. (Scheme 136)
3. Inspect apply ring and spring assembly for damage. Inspect piston and piston seals for damage. Inspect 2nd clutch housing for damaged inner piston seal. (Scheme 138)

1. Install Adapter (J-41992-3) into NEW 2nd clutch piston. Install piston and adapter into Protector (J-41992-1). Install piston assembly into 2nd clutch housing. Center inner seal protector onto hub by pressing down on center of protector. Install Piston Installer (J-41992-2) onto protector. Legs of installer go into slots of protector. Use hand pressure to press down on installer until piston is seated. (Scheme 140)
2. Install 2nd clutch spring assembly into housing. Install retaining ring. (Scheme 137) Install waved plate. Install apply plate into 2nd clutch housing with DN or DOWN marking toward piston. Install composition plates and steel plates, starting with composition plate and alternating each plate. Install backing plate and retaining ring. (Scheme 136)

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Note. If check ball valve does not leak, DO NOT replace.

Remove check ball valve from housing using 1/4" drift and hammer. (Scheme 141) Tap in NEW check ball assembly using same drift and hammer. (Scheme 142)

Scheme 141

Scheme 142

Inspect reverse band for cracks, scoring, lining separation or wear on fiber material. Inspect apply lug for cracks. Replace components as necessary. (Scheme 74)

Using appropriate spring compressor, compress 4th clutch spring assembly. Remove snap ring from driven sprocket support assembly. (Scheme 143) Remove spring compressor, spring assembly and 4th clutch piston from driven sprocket support assembly. Remove inner seal from driven sprocket support assembly hub. Remove oil seal rings and 4-lobed ring seals from driven sprocket support assembly. (Scheme 144) Remove outer seal from piston. (Scheme 145)

1. Inspect driven sprocket support components for the following: Worn or cut oil seal rings. Rolled or cut second clutch housing oil seal ring seals. Damage to piston seal surface in driven sprocket support. Blocked or porous oil passages in driven sprocket support. A leaking or missing cup plug. Damaged 4th clutch piston. Cracked or distorted 2nd clutch housing thrust washer. Distorted or missing springs in 4th clutch spring assembly. Driven sprocket bearing assembly for foreign material and missing, flat or damaged rollers.
2. Replace Teflon oil seal rings if cut or damaged, or if complete overhaul is being performed. Check all seal ring grooves for debris, burrs or damage. (Scheme 144)

1. Lubricate NEW inner and outer seal with ATF prior to installation. Install outer seal on 4th clutch piston. (Scheme 145) Install inner 4th clutch piston seal onto driven sprocket support hub. (Scheme 146)
2. Install 4th clutch piston into driven sprocket support and align components. Install 4th clutch spring assembly into piston. (Scheme 144) Using spring compressor, compress spring assembly and install snap ring. (Scheme 143) Lubricate NEW oil seal rings for 2nd clutch housing. Install oil seal rings and 4-lobed ring seals onto driven sprocket support hub. (Scheme 144)

2nd & 4th Clutch Functional Check

1. For this test, attach driven sprocket support assembly and 2nd clutch housing thrust washer onto 2nd clutch housing assembly. (Scheme 147)
2. Apply 20 psi (138 kPa) of compressed air to feed holes marked 2 and 4, and listen for 2nd and 4th clutch application. (Scheme 148) Hold pressure for 5 seconds. If clutches do not apply and hold, disassemble driven sprocket support components.
3. Inspect all seals and clutches for proper assembly. Reassemble and repeat functional check. When clutches apply and hold correctly, remove driven sprocket support assembly and 2nd clutch housing thrust washer from 2nd clutch housing assembly. (Scheme 147)

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Using Driver Handle (J-8092), Bearing Remover (J-34129) and hammer, drive driven sprocket support bearing from support. (Scheme 149) To reassemble, position driven sprocket support bearing assembly so markings on edge of bearing are facing up. Using Driver Handle (J-8092), Bearing Installer (J-34126) and hammer, seat bearing flush to or below support hub. (Scheme 150)

Scheme 149

Scheme 150

1. Install selective thrust washer and thrust bearing assembly onto input clutch housing assembly. (Scheme 73) Using small screwdriver, align 2nd clutch teeth. Install 2nd clutch housing assembly onto 2nd clutch hub of input clutch housing assembly.
2. Install Final Drive/Clutch Remover/Installer (J-33381-A) into 2nd clutch housing and input clutch housing. Sprag clutch assemblies will also be attached. (Scheme 72) Tighten threaded rod until rod is finger tight.

DRIVE SPROCKET & TURBINE SHAFT

Note. DO NOT damage grooves under oil seal rings.

Cut oil seal rings from turbine shaft. Remove oil seal rings. Remove drive sprocket retaining ring. Remove drive sprocket from turbine shaft. (Scheme 151)

1. Inspect driven sprocket and drive sprocket for the following: Worn or chipped teeth. Uniform teeth size. Stripped or damaged splines. Bearing surface damage. Replace components as necessary. (Scheme 152)and (Scheme 153).
2. Inspect 4th clutch shaft, driven sprocket and drive sprocket thrust washers for wear or cracks.
3. Inspect turbine shaft for a cracked sleeve, damaged bushing journals or stripped or damaged splines. Replace components as necessary.

1. Insert turbine shaft into drive sprocket and install retaining ring. (Scheme 151)
2. Install Turbine Shaft Seal Installer/Expander (J-29569-1) onto chain side of turbine shaft. Coat turbine shaft seal installer/expander with petroleum jelly. Slide turbine shaft oil seal rings into position. (Scheme 154)
3. Using Turbine Shaft Seal Installer/Compressor (J-29569-2), size chain side turbine shaft oil seal rings. (Scheme 155)
4. Install Turbine Shaft Seal Installer/Expander (J-29829-1A) onto converter side of turbine shaft. Coat turbine shaft seal installer/expander with petroleum jelly. Slide turbine shaft oil seal ring into position. (Scheme 156)
5. Using Turbine Shaft Seal Installer/Compressor (J-29829-2), size converter side turbine shaft oil seal ring. (Scheme 157)

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Inspect drive chain assembly for cracks, binding links or damage. Check input speed sensor reluctor wheel for damaged teeth, worn or damaged thrust surface and damaged or missing locating pins. Replace components as necessary. (Scheme 158)

Note. For drive and driven sprocket component reassembly, see TRANSAXLE REASSEMBLY .

Scheme 158

1. Inspect 4th clutch for the following conditions: Wear or damage to steel plates. Peened splines, flaking, or worn composition plates.
2. Inspect 4th clutch shaft for the following: Cut or worn 4th clutch plate splines. Stripped input sun gear splines. Damaged bushing journal. Cracks or damage to hub or shaft.

Replace components as necessary. (Scheme 68)

Note. For 4th clutch component reassembly, see TRANSAXLE REASSEMBLY .

CASE COVER COMPONENTS

Note. DO NOT remove any bore plugs unless inspection indicates replacement is necessary.

Remove manual valve. Remove 3-4 accumulator piston cylinder and 3-4 accumulator piston "O" ring seal. Use low pressure compressed air from valve body side if necessary for removal. Remove 3-4 accumulator piston outer and inner spring, piston and pin from valve body side of case cover. Remove actuator feed limit valve spring retainer, spring and valve. (Scheme 159)

1. Inspect 3-4 accumulator piston cylinder for porosity, scored pin or nicked or grooved piston sleeve. Inspect piston pin for scoring and free movement in piston bore. Inspect springs for distorted or broken coils. Inspect piston cylinder for porosity or cracks. Inspect for rough or scored seal surface, or cut seal. Inspect check ball, spring and bore plug. (Scheme 159)
2. DO NOT remove blow-off check balls unless damaged. Inspect manual valve, link and spring link for damage. Check manual valve for binding or looseness in case cover. Check case cover plugs and orifice cup plug. Replace plugs if loose, plugged or missing.
3. Inspect shaft bearing for damage. DO NOT remove bearing unless bearing is damaged. Inspect oil seal for missing garter spring or for cut lip seal.
4. Inspect case cover for porosity, interconnected fluid passages, cracks or rough machined surfaces.
5. Inspect input speed sensor for damaged or missing magnet, damaged housing, bent or missing electrical terminals, or damaged speed sensor clip.

Bearing Replacement

Note. When installing NEW bearing, part number should be visible (facing upward).

Place case cover on clean flat surface with spacer plate mating surface up. Using Driver Handle (J-8092), Bearing Remover/Installer (J-41991) and hammer, drive out bearing from case cover. (Scheme 160) To install, place case cover on clean flat surface with case mating surface up. Drive bearing into case cover. (Scheme 161)

Install NEW 3-4 accumulator piston cylinder "O" ring seal onto 3-4 accumulator piston cylinder. Install 3-4 accumulator piston outer and inner spring into 3-4 accumulator piston cylinder. Install NEW 3-4 accumulator piston seal onto 3-4 accumulator piston. Insert 3-4 accumulator piston into 3-4 accumulator piston cylinder. Using a slight twisting motion, insert 3-4 accumulator piston cylinder into case cover. Insert 3-4 accumulator piston pin through front of case cover and into 3-4 accumulator piston. Install manual valve into case cover. Install actuator feed limit valve, spring and spring retainer into case cover. (Scheme 159)

Scheme 159

Scheme 160

Scheme 161

Note. When drive axle is removed from transaxle for any reason, inspect axle sealing surface (tripot shank) for corrosion. If corrosion is evident, clean surface with 320-grit cloth or equivalent. Clean off any remaining debris with ATF. Wipe surface dry and reinstall drive axle free of any build up.

Install NEW left axle shaft oil seal onto Left Side Axle Seal Installer (J-34115). Using left side axle seal installer and mallet, install left side axle oil seal assembly. (Scheme 162)

Scheme 162

Inspect output shaft for damaged bushing journals, stripped splines or retaining ring groove damage. (Scheme 17)

Check for damaged connector, cracked housing, signs of rotor damage or cuts or nicks on seal. (Scheme 16)

Cleaning

Clean control valve body thoroughly in clean solvent. Move valves with a pick or small screwdriver to dislodge any dirt or debris. Use air nozzle to dry control valve body and to blow out all passages. Gently probe small passages with a piece of identification tag wire or equivalent.

1. Inspect control valve body for worn or damaged oil pump drive shaft bearing journal (not serviceable separately from control valve body), damaged or porous casting, damaged sealing surfaces and debris in fluid passages.
2. Before disassembly, inspect control valve body components using small pick or screwdriver for valves binding or sticking in bores or bushings, broken, missing or damaged springs, missing or damaged retainers, damaged solenoid valves or debris in valve line-ups or solenoid valves.
3. During disassembly, inspect control valve body for worn or damaged valves, valve bores or bushings, broken, missing or damaged springs, missing or damaged retainers, damaged solenoid valves, debris in valve line-ups or solenoid valves.
4. Inspect Transmission Fluid Pressure (TFP) manual valve position switch assembly for damaged electrical connector terminals, damaged seals, damaged switch membranes or debris on switch membranes. (Scheme 47)

Thoroughly clean and air dry control valve body. Remove each valve train, noting location of each component. Some valves are under spring pressure, cover bores when removing retainers. Remove retainers with small screwdriver. Position valves, springs and bushings on clean surface in order removed. (Scheme 163)& (Scheme 164).

To reassemble valve body components, reverse disassembly procedure. Ensure all components are installed in original locations. (Scheme 163)& (Scheme 164).

Scheme 163

Scheme 164

1. Inspect control valve body spacer plate for plugged holes, damaged sealing surfaces, or plugged or damaged screen/seal assemblies. Inspect each check ball seat on spacer plate for excessive peening. Place check ball on each seat. Using flashlight, look for visible light between check ball and seat. (Scheme 165) If light is visible between check ball and seat, replace spacer plate. For check ball locations (Scheme 53)and (Scheme 54).

Scheme 165

OIL PUMP ASSEMBLY

Remove oil pump cover bolt and oil pump cover. Remove pump rotor, vane rings, vanes, oil seal ring and slide "O" ring seal. Remove outer and inner oil pump prime springs, slide seal and slide seal support. Remove slide pivot pin. Remove outlet screen. (Scheme 166)

1. Inspect oil pump for the following: Worn, scored or gouged pump slide. Cracks, wear or damage to rotor or vanes. Cuts or damage to seals. Broken priming springs. Damaged oil pump drive shaft bearing (bearing is not serviced separately from rotor). (Scheme 166)
2. Inspect oil pump body for the following: Porosity Worn, scored or damaged pump pocket. Interconnected oil passages. Damaged machined surfaces.
3. Inspect pump outlet screen for damage or debris. Inspect oil pump cover for cracks, wear or gouges from pump vanes.
4. Measure pump rotor, oil pump vanes and oil pump slide. (Scheme 167) Select proper replacement size. See «OIL PUMP COMPONENT SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table.
5. Install outlet screen into oil pump body. Install slide seal support and slide seal into slot on pump slide. Install pump slide and slide pivot pin into pump body.
6. Install outer and inner priming springs into pump body. Install 1st vane ring into pump body. Insert pump slide "O" ring seal and slide oil seal ring into pump slide. (Scheme 166)
7. Insert rotor into pump body. Install pump vanes into rotor. Pump vanes must be flush with top of rotor. Install 2nd vane ring onto rotor. Install pump cover and bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).

OIL PUMP COMPONENT SPECIFICATIONS

Scheme 166

Scheme 167

Inspect wiring harness for cut or pinched wires, cut wire insulation, bent or broken electrical connectors or damaged terminals. (Scheme 168)

Scheme 168

CASE SIDE COVER

Note. Case side cover gasket and channel plate seal may be reused if not damaged.

Inspect case side cover for damaged or porous gasket sealing surfaces, and damaged or stripped bolt holes. Inspect case side cover gasket and channel plate seal for damage. (Scheme 169)

Scheme 169

THERMO ELEMENT ADJUSTMENT

If thermo element replacement is necessary, remove retainers, pins and thermo element. Remove plate element. (Scheme 170) For NEW element, set thermo pin height with Height Gauge (J-34094-A). (Scheme 171) Install plate element. Install pin and retainer assemblies, and set height with height gauge. Install NEW thermo element. "V" shape in thermo element must contact element plate.

Scheme 170

Scheme 171

Remove servo piston cylinder from servo cover. Remove "O" ring seal from servo piston cylinder. Remove piston assembly, servo piston spring and servo exhaust screen from cylinder. Remove servo piston seal from piston. Using small screwdriver, remove retaining ring from servo piston pin. Remove servo piston, cushion spring and spring retainer from servo piston pin. (Scheme 172)

Inspect 2-1 manual band servo components for the following

1. Damaged, worn or porous servo piston cylinder.
2. Damaged, worn or porous servo piston.
3. Damaged or worn servo piston pin.
4. Broken or damaged servo piston spring.
5. Broken or damaged servo piston cushion spring.
6. Damaged or plugged servo exhaust screen.
7. Damaged servo cover seal.
8. Damaged servo piston seal.
9. Damaged servo piston cylinder "O" ring seal.

Install servo piston spring retainer, cushion spring and servo piston onto servo piston pin. Install servo piston pin retaining ring. Install servo piston seal onto piston. Lubricate seal with ATF. Install servo exhaust screen and servo piston cylinder "O" ring seal onto cylinder. Lubricate "O" ring seal with ATF. Attach servo piston spring to piston assembly. Install servo piston assembly into cylinder assembly and set assemblies aside.

Scheme 172

1. Remove 7 remaining accumulator cover bolts from accumulator assembly. Remove accumulator cover and spacer plate from accumulator housing. Disassemble 1-2 and 2-3 accumulator pistons, piston pins, outer springs and cushion springs from accumulator housing (springs are model dependent). Remove piston oil seal rings from 1-2 and 2-3 accumulator pistons. (Scheme 173)
2. Disassemble 2-1 manual band servo and forward band servo oil pipes, lube oil pipe assembly from accumulator cover, and 2-1 manual band servo cover. Disassemble lube oil pipe, hose clamps, oil hose, lube oil pipe retainer and lube oil pipe with washer. (Scheme 174)

1. Inspect accumulator housing, accumulator cover spacer plate and accumulator cover for the following: Damaged oil pipe holes in accumulator cover. Damaged, improperly machined or porous accumulator cover. Bent or damaged accumulator cover spacer plate. Stripped or damaged bolt holes in accumulator housing. Damaged, worn, improperly machined or porous accumulator housing. Leaking, loose or missing cup plugs in accumulator housing.
2. Inspect accumulator pistons, springs, seals and pins for the following: Broken or collapsed piston outer springs. Broken or collapsed piston cushion springs. Bent or worn accumulator piston pins. Damaged, worn or porous accumulator pistons. Damaged accumulator piston seals.
3. Inspect servo and lube oil pipe components and 2-1 manual band servo cover for the following: Damaged lube, and servo oil pipe holes in servo cover. Damaged, improperly machined or porous servo cover. Bent, plugged or damaged lube and servo oil pipes. Plugged or damaged lube oil hose. Damaged hose clamps and/or lube oil pipe retainer. Missing lube oil pipe washer.

1. Install piston oil seal rings onto 1-2 and 2-3 accumulator pistons. Lubricate oil seal ring with ATF. Assemble 1-2 and 2-3 piston pins and pistons. Assemble 1-2 and 2-3 accumulator piston springs and piston assembly into accumulator housing. (Scheme 173)
2. Assemble accumulator spacer plate and cover onto accumulator housing. Install accumulator bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
3. Assemble lube oil pipe, oil hose, hose clamps, pipe retainer and pipe with washer. (Scheme 174) Install 2-1 manual band servo and forward band servo oil pipes into accumulator assembly. Install 2-1 manual band servo and forward band servo oil pipes into 2-1 manual band servo cover. Install lube oil pipe assembly into accumulator assembly.

Scheme 173

Scheme 174

1. Inspect for damaged sealing surface. Inspect for dented or cracked bottom pan surface. Inspect oil pan gasket for bent or damaged seal core, damaged rubber seal surface or damaged gasket. Check oil pan magnet for damage or misalignment. Clean oil pan, gasket and magnet. (Scheme 16)

Dissemble servo piston spring from servo assembly. Remove servo piston oil seal ring from servo piston. Remove servo pin retaining ring from servo piston pin. Disassemble servo piston, servo piston cushion spring, retainer and servo piston pin. (Scheme 16)

Inspect forward band servo components for the following

1. Damaged, worn or porous servo piston.
2. Damaged servo piston oil seal ring.
3. Damaged, worn or porous servo cover.
4. Damaged servo cover seal.
5. Broken or collapsed servo piston return spring.
6. Broken or collapsed servo piston cushion inner spring.
7. Broken or collapsed servo piston cushion outer spring.
8. Damaged or worn servo piston apply pin.

(Scheme 175)

Assemble servo piston, servo piston cushion springs, retainer and servo piston pin. Install servo pin retaining ring onto servo piston pin. Install servo piston oil seal ring onto servo piston. Install servo piston spring onto servo assembly. (Scheme 175)

Scheme 175

Remove return spring from reverse band servo assembly. Remove oil seal ring from servo piston. Using a small screwdriver, remove retaining ring from servo piston apply pin. Disassemble servo piston, servo piston cushion springs, servo piston cushion spring retainer and servo piston apply pin. (Scheme 176)

Inspect reverse band servo components for the following

1. Damaged, worn or porous servo piston.
2. Damaged servo piston oil seal ring.
3. Damaged, worn or porous servo cover.
4. Damaged servo cover "O" ring seal.
5. Damaged servo cover retaining ring.
6. Broken or collapsed servo piston return spring.
7. Broken or collapsed servo piston cushion springs.
8. Damaged or worn servo piston apply pin.

(Scheme 176)

Assemble servo piston, cushion springs, cushion spring retainer and servo piston apply pin. Install retaining ring onto servo piston apply pin. Install oil seal ring onto servo piston. Install return spring onto servo assembly. (Scheme 176)

Scheme 176

TRANSAXLE REASSEMBLY

Note. End play checks performed during TRANSAXLE DISASSEMBLY procedure must be rechecked at appropriate reassembly stage. For thrust washer, thrust bearing, bushing and seal installation direction and location during reassembly, refer to appropriate illustration. (Scheme 188)- (Scheme 192).

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

1. Install shift and park linkage components into case. See «PARKING SYSTEM COMPONENTS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under COMPONENT DISASSEMBLY & REASSEMBLY. Install final drive internal gear assembly into case. Align parking pawl with parking pawl actuator. Using long screwdriver, install retaining ring into case. (Scheme 86)
2. Position transaxle with oil pan flange facing down. Ensure sun gear thrust bearing is installed into differential carrier. Install differential carrier sun gear. Step in sun gear must be pointing toward parking gear. Install parking gear. Install internal gear thrust bearing into differential carrier. Ensure bearing is positioned properly. Install sun gear shaft into differential carrier. (Scheme 104) Install differential carrier into case. (Scheme 177)
3. Install selective thrust washer and thrust bearing onto differential carrier. Install seal onto case extension. Install case extension onto transaxle case. (Scheme 56) Install and tighten 2 case extension bolts only until case extension is seated into case. DO NOT torque bolts.
4. Position transaxle case with flange for case cover facing up. Install forward band into case. Locate band onto forward band anchor pin and apply pin feature in case opening. Install thrust washer onto final drive internal gear. (Scheme 85)
5. Install 1-2 support drum. (Scheme 84) Position 2-1 band on anchor pin. (Scheme 83) Install reaction sun gear and drum. (Scheme 82) Ensure sun gear and drum fully engage 1-2 support roller clutch. Check roller clutch for correct operation. (Scheme 111)
6. Install reaction carrier/sun gear thrust bearing onto reaction carrier. Install reaction carrier into transaxle case and rotate carrier so pinions engage reaction sun gear. Install thrust bearing and lube dam onto input carrier. Install input carrier into transaxle case and rotate carrier so pinions engage reaction carrier internal gear. (Scheme 114)
7. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates. Install input clutch roller clutch and sprag assemblies into case using Final Drive/Clutch Installer (J-33381). DO NOT install 2nd clutch housing, thrust bearing or thrust washer at this time.
8. Check input clutch housing end play. See «INPUT CLUTCH HOUSING END PLAY CHECK»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under TRANSAXLE DISASSEMBLY. Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be.0-.006" (.0-.15 mm). If clearance is not as specified, use different thrust washer. See «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Remove input clutch assembly. INPUT CLUTCH THRUST WASHER IDENTIFICATION Washer ID No. Color Thickness - In. (mm) 1 Orange/Green.114-.118 (2.90-3.00) 2 Orange/Black.120-.124 (3.05-3.15) 3 No Color.126-.130 (3.20-3.30) 4 White.132-.136 (3.35-3.45) 5 Blue.138-.142 (3.50-3.60) 6 Pink.144-.148 (3.65-3.75) 7 Brown.150-.154 (3.80-3.90) 8 Green.156-.159 (3.95-4.05) 9 Black.161-.165 (4.10-4.20) 10 Purple.167-.171 (4.25-4.35) 11 Purple/White.173-.177 (4.40-4.50)
9. Check for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25-degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) has splines with 10-degree sides. Install reverse reaction drum. (Scheme 75)
10. Install reverse band into case, locating band on anchor pins. (Scheme 74) Install selective thrust washer and thrust bearing onto input clutch assembly. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub. (Scheme 73)
11. Install final drive/clutch installer into assembled input and second clutch housing assemblies. Tighten threaded rod of final drive/clutch installer until rod is finger tight. Using final drive/clutch installer, lift input and second clutch housing assembly, and install input and second clutch housing assembly into case. (Scheme 72) Ensure input clutch housing assembly is fully seated. Ensure second clutch housing is.500" (13 mm) above top of reverse band assembly.
12. Install thrust washer onto driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case. (Scheme 71) Ensure support is flush with or below case.
13. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. (Scheme 70). Assemble drive and driven sprockets into drive chain assembly as follows: If old drive link is being reinstalled, assemble drive link and sprockets with master link (different color link) facing in same direction as removed. See «DRIVE & DRIVEN SPROCKETS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under TRANSAXLE DISASSEMBLY. If NEW drive link assembly is being installed, assemble drive link and sprockets with master link facing upward.
14. Install drive link assembly and sprockets into case. A slight rocking motion may be required to work sprockets into place. Install input speed sensor reluctor wheel onto drive sprocket. (Scheme 70) Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See «DRIVE & DRIVEN SPROCKETS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under TRANSAXLE DISASSEMBLY.
15. Install 4th clutch shaft thrust washer onto driven sprocket. Insert 4th clutch shaft into transaxle case through driven sprocket. (Scheme 68) Shaft must fully seat into input sun gear. Install drive link lube scoop into case.
16. Install fourth clutch apply plate over fourth clutch shaft assembly and into driven sprocket support with machined side towards driven sprocket. Install remaining 4th clutch plates, starting with composition plate and alternating with steel plates. Clutch plates should align in driven sprocket support. (Scheme 68)
17. Install pistons and pins into case cover. Install springs into case cover. (Scheme 159) Install case cover gaskets. (Scheme 67) Install 4th clutch shaft and drive sprocket thrust washers onto case cover. (Scheme 66)
18. Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch plates. (Scheme 17) Install case cover bolts. See «CASE COVER BOLT SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Tighten case cover bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications). CASE COVER BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 1.3 (32) 2 0.24 (6) 1.6 (40) 3 0.31 (8) 2.0 (50) 4 0.24 (6) 1.2 (30) (1) For bolt location, refer to illustration. (Scheme 65)
19. Install oil dam into case. (Scheme 63) Connect manual valve link to manual valve. (Scheme 62) Install manual shift detent and bolt. (Scheme 61) Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
20. Install input speed sensor and clip into case cover. (Scheme 64)
21. On 2 wheel drive models, check front differential carrier end play. See «FRONT DIFFERENTIAL CARRIER END PLAY CHECK»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__front-differential-carrier-end-play-check) under TRANSAXLE DISASSEMBLY. Install appropriate thrust washer on to input shaft and hold in position with petroleum jelly. See «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Tighten case extension bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
22. Install oil pump drive shaft. (Scheme 55) Install 2 large check balls and 4 small check balls into control valve body. (Scheme 54) Install 4 check balls into case cover. (Scheme 53) Use petroleum jelly to hold check balls in position.
23. Install solenoid screen/seal assemblies into spacer plate. Install case cover guide pin into case cover. Install valve body-to-spacer plate gasket, spacer plate and case cover-to-spacer plate gasket onto control valve body. Install bolts to hold spacer plate and gaskets onto control valve body. (Scheme 178)
24. Install control valve body onto case cover. Use case cover pin and turbine sleeve in case cover as guides. Ensure check balls do not drop out of control valve body during reassembly. (Scheme 179) Install manual valve position switch onto control valve body. (Scheme 51)
25. Install control valve body bolts. See «VALVE BODY BOLT SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Finger tighten bolts to prevent cross-threading. Tighten bolts in a spiral pattern starting with bolts at center of control valve body. If bolts are tightened at random, valve bores may become distorted and prevent proper valve operation. Tighten valve body bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
26. Install oil pump assembly onto control valve body. (Scheme 49) Install oil pump bolts in specified locations. See «OIL PUMP BOLT SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications). Install electronic components and wiring harness. Ensure wire connectors are installed in correct locations. (Scheme 46) VALVE BODY BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 2.6 (65) 2 0.24 (6) 2.4 (60) 3 0.24 (6) 1.2 (30) 4 0.24 (6) 1.8 (45) 5 0.24 (6) 2.2 (55) 6 0.24 (6) 3.7 (95) 7 0.31 (8) 3.5 (90) 8 0.24 (6) 0.8 (20) 9 0.24 (6) 3.3 (85) (1) For bolt location, refer to illustration. (Scheme 50) OIL PUMP BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 0.8 (20) 2 0.24 (6) 3.7 (95) 3 0.24 (6) 3.3 (85) (1) For bolt location, refer to illustration. (Scheme 48)
27. Install side cover gasket and seal onto transaxle case. (Scheme 15) Install case side cover. (Scheme 45) Tighten side cover bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
28. Install 2-1 manual band servo and cover gasket into case. Lubricate gasket with ATF. (Scheme 180) Ensure servo piston pin engages band. Install accumulator and 2-1 manual band servo cover assembly into case. (Scheme 181) Install lube oil pipe into case at lube hole for differential carrier internal gear. Lock lube oil pipe retainer into case. (Scheme 43) Install cover bolts for 2-1 manual band servo. Install accumulator cover and bolts. (Scheme 42) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
29. Using socket and mallet, install NEW oil filter seal. (Scheme 182) Install oil filter and pan gasket into case. Install oil pan and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
30. Position transaxle so oil pan is facing up. Install servo cover seal onto forward band servo cover. Install forward band servo assembly into servo cover. Pivot servo assembly into servo cover to prevent piston oil seal ring from being damaged. Install servo and cover assembly into case. (Scheme 41)
31. Using long screwdriver, pry against work bench to compress forward band servo assembly. (Scheme 40) Hold servo assembly compressed. Install 3 forward band servo cover bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__torque-specifications).
32. Position transaxle so oil pan is facing down. Install "O" ring seal onto reverse servo cover. Install servo and cover assembly into case. (Scheme 39) Use a long screwdriver to depress reverse band servo cover by prying against transaxle holding fixture. (Scheme 38) Hold reverse band servo assembly compressed. Using a small screwdriver, install reverse band servo cover retaining ring.
33. Install VSS. Install "O" ring onto turbine shaft. Install torque converter.
34. On 2WD models, affix outboard and inboard drive shaft retaining rings onto output shaft. DO NOT push to hard during installation of output shaft, or damage to bushings or bearings may occur. Carefully install output shaft into transaxle. Extend shaft through differential side gear. On AWD models, DO NOT install output shaft until after performing «TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK»(/buick/century/vi-1997-2005/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__transmission-to-transfer-case-end-play-check) and reinstalling transfer case.

CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES

TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK

Note. ATF circulates between transaxle and transfer case. In situations where transaxle related failures circulate debris into transfer case, transfer case must be disassembled, cleaned, and inspected for damage.

1. Position transaxle so case side cover is facing down. Install final drive sun gear shaft. (Scheme 37) Use petroleum jelly to retain parking gear thrust bearing to parking gear. Install parking gear thrust bearing and parking gear. (Scheme 36) Install final drive sun gear. (Scheme 34)
2. Install bolts to end play checking tool and tighten securely to prevent tool deflection during end play measurement. (Scheme 76) Hand tighten end play checking tool to remove end play. Install gauge bar onto case mounting surface.
3. Measure distance from case mounting surface, bottom of gauge bar to top of final drive sun gear. (Scheme 183) This measurement is dimension "A". Remove gauge bar and end play checking tool.
4. Install gauge bar onto carrier. Measure distance from bottom of gauge bar to transfer case. (Scheme 184) This measurement is Dimension B1. Measure distance from bottom of gauge bar to thrust bearing. (Scheme 185) This measurement is Dimension B2. Subtract Dimension B2 from Dimension B1. This is Dimension "B". For available thrust washer sizes, refer to illustration. (Scheme 186)
5. Remove gauge bar from transfer case. Remove final drive sun gear. Install selective washer. (Scheme 35) Install final drive sun gear. (Scheme 34)

Scheme 183

Scheme 184

Scheme 185

Scheme 186

TRANSFER CASE INSTALLATION

1. Install case extension seal. (Scheme 30) Line up notch to hole in case and install oil dam. (Scheme 31)
2. Install transfer case lower brace. (Scheme 29) Install and hand tighten transfer case lower brace bolts. Rotate transaxle so oil pan is facing floor. Install transfer case assembly onto transaxle. (Scheme 187)
3. Install 5 transfer case-to-transaxle bolts. (Scheme 27) Torque bolts in sequence. Tighten transfer case bolts No. 1 and 2 in 2 passes; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an additional 160 degrees. Tighten transfer case bolt No. 3; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an additional 70 degrees. Tighten transfer case bolts No. 4 and 5 to 30 ft. lbs. (40 N.m).
4. Install transfer case side brace to case and hand tighten bolts. Tighten bolts to 23 ft. lbs. (31 N.m) in numerical sequence (1, 2, 3, 4, 5). (Scheme 26) Install transfer case lower brace-to-transaxle bolt and tighten to 42 ft. lbs. (56 N.m) (Scheme 25) Tighten transfer case lower brace-to-transaxle bolts to 23 ft. lbs. (31 N.m).
5. Affix outboard and inboard drive shaft retaining rings onto output shaft. DO NOT push to hard during installation of output shaft, or damage to bushings or bearings may occur. Carefully install output shaft into transaxle. Extend shaft through differential side gear.

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

See also:
• CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES
• TORQUE SPECIFICATIONS
• VEHICLE SPEED SENSOR RELUCTOR WHEEL
• INPUT CLUTCH HOUSING CHECK BALL VALVE
• TRANSAXLE REASSEMBLY
• FRONT DIFFERENTIAL CARRIER END PLAY CHECK
• TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK