Automatic Transaxle Overhaul & Testing - 4t65-e Buick Park Avenue II

APPLICATIONS

4T65-E TRANSAXLE APPLICATIONS

IDENTIFICATION

Transaxle has a metal identification plate and Service Replacement Transmission Assembly plate attached to rear face of transaxle. (Scheme 48) Transaxle RPO codes are M15, MN3 or MN7. 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. For model build information on each RPO code (Scheme 49)- (Scheme 51).

Scheme 48

Scheme 49

Scheme 50

Scheme 51

GEAR RATIOS

TRANSAXLE GEAR RATIOS

DESCRIPTION & OPERATION

Hydra-Matic 4T65-E transaxle is a fully automatic 4-speed unit consisting primarily of a 3-element hydraulic torque converter and converter clutch. Transaxle uses a variable capacity vane-type oil pump to supply all hydraulic pressure needed for operation.

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, a roller clutch, a sprag clutch, 3 bands and a compound planetary gear set. Final drive gear and differential assemblies are an integral part of transaxle.

Transaxle uses electronic shift solenoids, controlled by the Powertrain Control Module (PCM), to switch hydraulic pressure on or off. Another electronic solenoid controls Torque Converter Clutch (TCC) lock up. A Pulse Width Modulated (PWM) solenoid is used to control rate of TCC apply.

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

LUBRICATION

For additional information, see appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

RECOMMENDED FLUID

Use only Dexron-III Automatic Transmission Fluid (ATF).

FLUID CAPACITIES

The transmission/transaxle refill capacities given below are approximate. Correct fluid level should always be determined by marks on dipstick, rather than by amount of fluid added. DO NOT overfill transmission/transaxle. See FLUID CAPACITIES table.

FLUID CAPACITIES (1)

ON-VEHICLE SERVICE

The following components can be serviced without removing transaxle from vehicle.

1. Case Side Cover Pan
2. Converter-To-Flexplate Bolts
3. Cooler Lines
4. Drive Axles
5. Filler Pipe
6. Final Drive
7. Forward Servo
8. Reverse Servo
9. Shift Control Cable
10. Solenoids
11. Speed Sensor
12. Thermal Element
13. Transaxle Oil Pan
14. Transaxle Filter
15. Valve Body
16. Wiring Harness
17. 1-2 Manual Band Servo
18. 1-2 Or 2-3 Accumulator Assemblies

CONTROL VALVE BODY

See CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR (VSS) under TRANSAXLE DISASSEMBLY.

DRIVE AXLE SHAFTS

See appropriate AXLE SHAFTS article in AXLE SHAFTS & TRANSFER CASES.

OIL COOLER FLUSHING

1. If available, fill Line Flusher (J-35944) with solution, and install oil cooler and line flusher to transaxle cooler lines on transaxle. Follow manufacturer's instructions to flush oil cooler and cooler lines.
2. If line flusher is not available, flush cooler and cooler lines with a mixture of clean solvent and water. Flush cooler in both directions until all old fluid and debris are removed. If necessary, replace plugged or damaged cooler and/or lines.

TROUBLE SHOOTING

Note. For clutch and band applications, see CLUTCH & BAND APPLICATION table at end of TROUBLE SHOOTING.

PRELIMINARY INSPECTION

1. Check level and condition of transaxle fluid. Check PCM memory for stored Diagnostic Trouble Codes (DTCs). See HYDRA-MATIC 4T65-E ELECTRONIC CONTROLS article. If no DTCs are present, go to next step. If DTCs are present, diagnose and repair all PCM-related trouble codes. Clear PCM trouble code memory.
2. Perform road test. See «ROAD TEST»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__road-test) under PERFORMANCE TESTS. During road test, record shift points. If shift point timing or shifting is incorrect, see HYDRA-MATIC 4T65-E ELECTRONIC CONTROLS article.
3. If shift(s) is too harsh or too soft, see «LINE PRESSURE TEST»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__hydraulic-pressure-tests) under PERFORMANCE TESTS. For specific complaints, see appropriate condition(s) listed in SYMPTOM DIAGNOSIS.

SYMPTOM DIAGNOSIS

Note. PCM controls TCC, PWM solenoid, 1-2 and 2-3 shift solenoids.

Incorrect Line Pressure

Low fluid level. Thermo element plate pins are misadjusted or out of position. Damaged oil filter. Missing or damaged oil filter seal. Wiring harness is disconnected or damaged. Oil pump assembly components are damaged. Damaged pressure control solenoid. Solenoid "O" ring seals are missing or damaged. Valve retainer is missing or damaged. Torque signal regulator valve is binding or damaged. Pressure regulator valve, reverse boost valve, actuator feed limit valve, or low blow-off ball valve is binding or damaged.

Delayed Park To Reverse/Drive Engagement

Low fluid level. Low transaxle main line pressure. Damaged or rolled reverse or forward band servo piston oil seal ring. Reverse servo boost valve or forward servo boost valve is binding or damaged. Thermal element not functioning or damaged. TCC blow-off ball is not sealing, causing torque converter drain back. Input clutch assembly components are damaged.

Harsh Park To Reverse/Drive Engagement

High transaxle main line pressure. Reverse or forward band servo piston cushion spring broken or missing. No. 5 or No. 6 check ball is out of position or missing. Reverse or forward servo boost valve is binding or damaged. Thermal element is damaged or is not functioning properly.

Slips In Drive Or No Drive

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. Loose or damaged forward band servo oil pipe. Loose 2-1 manual band servo cover or accumulator cover bolts. Missing or damaged 2-1 manual band servo cover gasket. Damaged accumulator cover spacer plate. Forward band servo piston oil seal ring missing or damaged. Servo piston is damaged or is stuck in servo cover. Servo piston cushion spring or retainer is missing or damaged. Servo piston pin is not engaged to forward band. Forward band is worn or burned. Forward band is disengaged from anchor pin. Anchor pin is loose or missing. No. 3 check ball is missing. Torque converter stator clutch is not holding. Drive chain assembly is broken or drive or driven sprockets are damaged. Input clutch assembly components are damaged. 1-2 roller clutch assembly is damaged. Input carrier assembly or reaction carrier assembly components are damaged. Parking pawl assembly is broken or damaged. Sun gear shaft, internal gear assembly or carrier assembly components are damaged.

Slips In Reverse Or No Reverse

Low fluid level. Low transaxle main line pressure. Manual linkage misadjusted. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. Reverse band servo piston oil seal ring is missing or damaged. Servo piston is damaged or is stuck in case bore. Servo piston cushion springs or retainer is missing or damaged. Servo piston pin is not engaged to reverse band. Reverse band is worn or burned. Reverse band is disengaged from anchor pin. Anchor pin is loose or missing. Torque converter stator clutch is not holding. Drive chain assembly is broken or drive and driven sprockets are damaged. Input clutch assembly components are damaged. Reverse reaction drum splines are damaged. Input carrier or reaction carrier assembly components are damaged. Parking pawl assembly is broken or damaged. Sun gear shaft, internal gear assembly or carrier assembly components are damaged.

Locked Up In Drive/Reverse

Input carrier or reaction carrier assembly components are damaged. Parking pawl assembly is broken or damaged. Sun gear shaft, internal gear assembly or carrier assembly components are damaged.

No Park Range

Manual linkage misadjusted. Parking pawl assembly is broken or damaged. Parking pawl actuator is damaged. Actuator guide is damaged or debris is present.

Harsh Or Soft 1-2 Shift Feel

Low fluid level. Low or high transaxle main line pressure. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. 1-2 accumulator is misassembled upside down. Damaged or missing 1-2 accumulator piston oil seal ring. Damaged or missing 1-2 accumulator piston cushion spring or outer spring. Stuck or binding 1-2 accumulator piston. Debris in accumulator cover spacer plate passages. Control valve body components are damaged. Damaged 2nd clutch housing oil seal rings, or 4 lobe oil seal ring seals. 2nd clutch assembly components are damaged.

Harsh Or Soft 2-3/3-2 Shift Feel

Low fluid level. Low or high transaxle main line pressure. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. 2-3 accumulator is misassembled upside down. Damaged or missing 2-3 accumulator piston oil seal ring. Damaged or missing 2-3 accumulator piston cushion spring or outer spring. Stuck or binding 2-3 accumulator piston. Debris in accumulator cover spacer plate passages. Control valve body components are damaged. Plugged 3rd clutch oil passage in driven sprocket support assembly. 3rd clutch assembly components are damaged.

Harsh Or Soft 3-4/4-3 Shift Feel

Low fluid level. Low or high transaxle main line pressure. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. 3-4 accumulator is misassembled upside down. Damaged or missing 3-4 accumulator piston oil seal ring. Damaged or missing 3-4 accumulator piston outer spring. Stuck or binding 3-4 accumulator piston. Damaged 3-4 accumulator piston cylinder or "O" ring seal. Debris in control valve body or spacer plate passages. Control valve body components are damaged. Missing or damaged 4th clutch orifice. Damaged driven sprocket support assembly. 4th clutch assembly components are damaged.

High Or Low Upshift Or Downshift Speed

Incorrect calibration in PCM. Misadjusted or faulty throttle position sensor.

1st & 2nd Gear Only (2-3 Shift Solenoid Stuck On)

Faulty 2-3 shift solenoid. Debris in control valve body or spacer plate.

1st & 4th Gear Only (1-2 Shift Solenoid Stuck On)

Faulty 1-2 shift solenoid. 3-4 shift solenoid stuck on. Debris in control valve body or spacer plate.

2nd & 3rd Gear Only (1-2 Shift Solenoid Stuck Off)

Faulty 1-2 shift solenoid. 3-4 shift solenoid is stuck off. Missing or damaged shift solenoid "O" ring seal. Plugged or damaged solenoid screen/seal. Debris in control valve body or spacer plate. Stuck, binding or missing actuator feed limit valve.

3rd & 4th Gear Only (2-3 Shift Solenoid Stuck Off)

Faulty 2-3 shift solenoid. Missing or out of position 2-3 shift solenoid and retainer. Missing or damaged shift solenoid "O" ring seal. Plugged or damaged solenoid screen/seal. Debris in control valve body or spacer plate.

1st Gear Only

1-2 shift valve is stuck or binding. Debris in control valve body or spacer plate. Spacer plate and gaskets are misassembled. 2nd clutch assembly components are damaged. Damaged reverse reaction drum splines.

2nd Gear Only

1-2 shift valve is stuck or binding. Debris in control valve body or spacer plate. Input sun gear damaged. Input carrier planetary pinion damaged.

3rd Gear Only

Debris in control valve body or spacer plate. Spacer plate and gaskets are misassembled.

4th Gear Only

Debris in control valve body or spacer plate. Spacer plate and gaskets are misassembled.

Slipping Or No 1st Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. Loose or damaged forward band servo oil pipe. Loose 2-1 manual band servo cover or accumulator cover bolts. Missing or damaged 2-1 manual band servo cover gasket. Damaged accumulator cover spacer plate. Forward band servo piston oil seal ring missing or damaged. Servo piston is damaged or is stuck in servo cover. Servo piston cushion spring or retainer is missing or damaged. Servo piston pin is not engaged to forward band. Forward band is worn or burned. Forward band is disengaged from anchor pin. Anchor pin is loose or missing. 1-2 shift valve is stuck or binding. No. 3 check ball is missing. Input clutch assembly components are damaged. 1-2 roller clutch assembly is damaged.

Slipping Or No 2nd Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. 1-2 shift valve is stuck or binding. Debris in passages of control valve body or spacer plate. 2nd clutch housing oil seal rings damaged. Damaged 4 lobe oil seal ring seals. 2nd clutch housing bushings damaged or worn. 2nd clutch assembly components are damaged.

Slipping Or No 3rd Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. 2-3 shift valve or 3-2 manual downshift valve is stuck or binding. Debris in passages of control valve body or spacer plate. No. 4 or No. 9 check ball is missing or out of position. Plugged 3rd clutch oil passage in driven sprocket support assembly. 3rd clutch assembly components are damaged. 3rd sprag was installed backwards on inner race. Damaged 3rd clutch sprag assembly.

Slipping Or No 4th Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. 3-4 shift valve or 4-3 manual downshift valve is stuck or binding. Debris in passages of control valve body or spacer plate. Distortion or damage occurs at manual valve or at case cover, causing oil leak. Plugged 3rd clutch oil passage in driven sprocket support assembly. 4th clutch assembly components are damaged. 3rd sprag was misassembled backwards on inner race. Damaged 3rd clutch sprag assembly.

No Engine Braking In Manual 2nd Or Low Range

Loose or damaged 2-1 manual band servo oil pipe. Loose 2-1 manual band servo cover or accumulator cover bolts. Damaged accumulator cover spacer plate. Damaged or missing servo piston seal or servo piston cylinder "O" ring seal. Missing servo exhaust screen, allowing debris into cylinder. Misassembled 2-1 manual band servo. 2-1 manual band worn or burned. 2-1 manual band is disengaged from anchor pin. Anchor pin is loose or missing.

Converter Clutch Stuck On In All Gears

TCC control valve or TCC regulator apply valve is stuck or binding. Control valve body spacer plate and gaskets are misassembled or contain incorrect parts. Faulty torque converter. Pressure plate is stuck in applied position.

Converter Clutch Stuck On In 2nd, 3rd & 4th Gear

TCC regulator apply valve is stuck or binding, or apply valve spring is missing or damaged. TCC control valve spring is missing or damaged. Control valve body spacer plate and gaskets are misassembled or contain incorrect parts. Faulty torque converter.

Harsh Converter Clutch Apply Or Release

TCC regulator apply valve is stuck or binding, or apply valve spring is missing or damaged. TCC control valve spring is missing or damaged. Control valve body spacer plate and gaskets are misassembled or contain incorrect parts. Faulty torque converter.

Converter Clutch Apply Rough, Slips Or Shudders

TCC regulator apply valve is stuck or binding, or apply valve spring is missing or damaged. Control valve body spacer plate and gaskets are misassembled or contain incorrect parts. TCC blow-off ball valve or spring is damaged or not sealing. Turbine shaft "O" ring seal is damaged or missing. Turbine shaft oil seal rings are damaged or missing. Turbine shaft is damaged. Turbine shaft bushing is worn or damaged. Faulty torque converter.

No TCC Apply

TCC PWM solenoid is stuck off. TCC control valve or TCC regulator apply valve is stuck or binding. No. 10 check ball is missing or out of position. Control valve body spacer plate and gaskets are misassembled or contain incorrect parts. TCC blow-off ball valve or spring is damaged or not sealing. Turbine shaft "O" ring seal is damaged or missing. Turbine shaft oil seal rings are damaged or missing. Turbine shaft is damaged. Turbine shaft bushing is worn or damaged. Faulty torque converter.

Scheme 52

CLUTCH & BAND APPLICATION

ROAD TEST

Note. Before road testing vehicle, engine and transaxle must be at operating temperature. Torque converter clutch will not engage if transaxle fluid has not reached a minimum temperature of 46°F (8°C), and engine coolant has not reached operating temperature of 122°F (50°C).

Road Test Procedure

Perform road test with scan tool connected to vehicle. Powertrain Control Module (PCM) calculates upshift points based primarily on throttle position and vehicle speed. When PCM determines a shift should occur, an electrical signal is sent to shift solenoids. Solenoids move shift valves to perform shift. A scan tool should be used during road test to monitor throttle position. Some scan tools are capable of recording shift point information. Check scan tool instruction manual to determine if this test is available.

Gear Selector Position "D" (Overdrive)

1. With gear selector in "D" (overdrive) position, steadily increase throttle pressure to accelerate vehicle. Using scan tool, monitor throttle position and vehicle speed. Note shift speed engagement points in 2nd gear, 3rd gear and overdrive gear. See appropriate shift speed specifications chart as a reference for proper shift speeds. Note Torque Converter Clutch (TCC) engagement point while in 3rd gear or 4th (Overdrive). (Scheme 53)- (Scheme 60). Ensure proper transaxle model specification is being referenced. (Scheme 48) NOTE: Ensure TCC engages in 3rd gear or overdrive during the following steps. On vehicles with PWM TCC solenoid, TCC engagement point may be hard to feel. Use scan tool to indicate TCC engagement and release points.
2. At vehicle speeds of 40-50 MPH, quickly depress accelerator to half-open position (part throttle detent downshift). TCC should release, and transaxle should immediately downshift to 3rd gear. The 1-2 shift solenoid should turn off and 2-3 shift solenoid should remain on.
3. At vehicle speeds of 40-50 MPH, quickly depress accelerator to wide open position (full throttle detent downshift). TCC should release, and transaxle should immediately downshift to 2nd gear, and 1-2 and 2-3 shift solenoids should turn off.
4. At vehicle speeds of 40-55 MPH, release accelerator pedal while moving gear selector to "3" (3rd gear) position. TCC should release, transaxle should downshift into 3rd gear, and engine braking should slow vehicle.
5. Move gear selector to "D" (overdrive) position, and accelerate to 40-45 MPH. Release accelerator pedal while moving gear selector to "2" (2nd gear) position. TCC should release, transaxle should downshift to 2nd gear immediately, and engine braking should slow vehicle.
6. Move gear selector to "D" (overdrive) position, and accelerate to 40 MPH. Release accelerator pedal while moving gear selector to "1" (1st gear) position. TCC should release, transaxle should downshift to 2nd gear and engine braking should slow vehicle. When vehicle speed is less than 37 MPH, transaxle should downshift to 1st gear.
7. With gear selector in "D" (overdrive) position, accelerate vehicle to overdrive gear with TCC applied. Release accelerator pedal, and lightly apply brakes. TCC should release. Vehicle should downshift to appropriate gear, depending on vehicle speed.

Gear Selector Position "3" (3rd Gear)

With vehicle stopped, move gear selector to "3" (3rd gear) position and steadily increase throttle pressure to accelerate vehicle. Note speeds at which vehicle shifts into 2nd and 3rd gears. Note when TCC engages while in 3rd gear.

Gear Selector Position "2" (2nd Gear)

With vehicle stopped, move gear selector to "2" (2nd gear) position. Accelerate vehicle and note speed at which vehicle shifts from 1st gear to 2nd gear. Accelerate vehicle to 25 MPH. Transaxle should not shift into 3rd gear, and TCC should not engage.

Gear Selector Position "1" (1st Gear)

With vehicle stopped, move gear selector to "1" (1st gear) position. Accelerate vehicle to 20 MPH. Transaxle should not upshift, and TCC should not engage.

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Inspection

Torque converter must be replaced for any of the following reasons.

1. Damage To Oil Pump Assembly
2. Metal Particles Present In Oil
3. Leaks In Hub Weld Area
4. Crankshaft Pilot Broken Or Damaged
5. Hub Scored Or Damaged
6. Stator Failure
7. Torque Converter Imbalance
8. Engine Coolant Contamination
9. Excessive End Play

Stall Speed Test

Manufacturer does not recommend testing torque converter stall speed.

Noise Test

1. Torque converter whine is usually noticed when vehicle is stopped and transaxle is in Reverse or Drive. Whine will increase when engine RPM is increased and will stop when vehicle is moving or when torque converter clutch is applied. Stall speed test is to ensure whine is coming from torque converter.
2. Start engine, and allow it to reach normal operating temperature. Apply parking and service brakes. Put transaxle in Drive. Depress accelerator to about 1200 RPM for less than 6 seconds. DO NOT depress accelerator for more than 6 seconds, or transaxle damage may occur. Torque converter noise will increase under this load.

Note. Torque converter whine should not be confused with pump whine, which is usually noticeable in Park, Neutral and all other gear ranges. Pump whine will vary with pressure.

Stator Check

1. Torque converter stator roller clutch can either remain locked up at all times or freewheel in both directions. If stator is freewheeling at all times, vehicle tends to have poor acceleration from a stop. Vehicle may act normal at speeds above 30-35 MPH.
2. If poor acceleration is noted, ensure exhaust system is not blocked, engine timing is correct and transaxle is in 1st gear when starting from a stop. If stator is locked up at all times, performance from a stop appears normal. Engine RPM and acceleration is limited at high speeds. Engine may overheat from this condition.

HYDRAULIC PRESSURE TESTS

Line Pressure

1. Before performing line pressure test, check fluid level and condition. Check manual control linkages for correct adjustment, and ensure engine is properly tuned.
2. Connect scan tool to vehicle. Start engine and check for Diagnostic Trouble Codes (DTCs). If DTCs are present, see HYDRA-MATIC 4T65-E ELECTRONIC CONTROLS article. If DTCs are not present, turn engine off. Connect oil pressure gauge to line pressure test port. (Scheme 61)
3. Start engine and allow it to warm to normal operating temperature. Using scan tool, access Pressure Control Solenoid (PCS) control test (PC Sol.). Using scan tool, increase pressure control solenoid current in increments of.1 amp. Allow pressure to stabilize for 5 seconds after each pressure change.
4. With engine at idle, read corresponding line pressure on oil pressure gauge. Compare PCS current reading on scan tool and line pressure reading on gauge. See «PCS CURRENT & LINE PRESSURE SPECIFICATIONS AT IDLE»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table.
5. Shift transaxle to specified shift position. Measure minimum line and full line pressure. See «LINE PRESSURE SPECIFICATIONS»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Record line pressure readings in all gear selector positions and compare recorded pressures to specifications.
6. If pressure readings are not as specified, refer to «SYMPTOM DIAGNOSIS»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__symptom-diagnosis) under TROUBLE SHOOTING for diagnosis.

PCS CURRENT & LINE PRESSURE SPECIFICATIONS AT IDLE (1)

LINE PRESSURE SPECIFICATIONS

Scheme 61

A visual inspection of torque converter may reveal converter is Blue from overheating. If torque converter has been removed from vehicle, stator roller clutch can be checked by inserting 2 fingers into splined inner race of roller clutch and trying to turn race in both directions. Inner race should turn freely clockwise but should not turn or should be difficult to turn counterclockwise.

End Play Check

Mount Torque Converter End Play Fixture (J-35138) and Dial Gauge (J-8001) on torque converter to check end play. End play should be 0-.020" (0-.50 mm). (Scheme 62)

Scheme 62

REMOVAL & INSTALLATION

See appropriate AUTOMATIC TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.

REVERSE BAND SERVO

1. Remove torque converter and turbine shaft "O" ring seal. Install Holding Fixture (J-28664-B) onto transaxle. (Scheme 63) Install transaxle and holding fixture into Base (J-3289-20). Insert pin into base to hold transaxle in desired position. Using a long screwdriver, depress reverse band servo cover by prying against holding fixture. Pry out retaining ring from reverse band servo cover. (Scheme 64)
2. Remove screwdriver. Servo assembly will push servo cover up. Using a 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 it out of servo cover. Servo assembly will push servo cover up. Remove servo cover, reverse band servo assembly and reverse band servo piston return spring.

Scheme 63

FORWARD BAND SERVO

Position transaxle so oil pan is facing up. Using a long screwdriver, depress forward band servo assembly cover by prying against work bench. Hold servo assembly and remove 3 forward band servo cover bolts. (Scheme 64) Remove screwdriver. Servo assembly will push servo cover out. If cover does not move, tap it with a rubber mallet. Remove servo cover and cover seal. Remove servo assembly. Remove piston return spring from forward band servo.

OIL PAN & FILTER

Remove 20 oil pan bolts. Remove oil pan and gasket. Using a screwdriver, pry oil filter out of case. Pry oil filter seal out of case. DO NOT damage case sealing surface. (Scheme 64) Inspect oil pan magnet for steel particles. Excessive amounts of steel shavings indicates internal transaxle damage. Using a screwdriver, pry metal crimping away from top of oil filter and pull oil filter apart. Inspect oil filter for clutch plate assembly material, steel particles and Bronze slivers, indicating bushing damage or internal transaxle damage.

Scheme 64

ACCUMULATOR ASSEMBLY & 2-1 MANUAL BAND SERVO

1. Remove 4 accumulator cover bolts from 1-2 and 2-3 accumulator cover. (Scheme 65) Remove 3 bolts from 2-1 manual band servo cover. Using a screwdriver, gently pry lube oil pipe retainer from case. Remove lube oil pipe from front differential carrier internal gear lube hole. (Scheme 66)
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 65

Scheme 66

CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR (VSS)

1. Position transaxle with control valve body cover facing up. Remove 17 case side cover (control valve body cover) bolts. (Scheme 67) Remove cover and gaskets. Using a 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 68)
2. Lift wiring harness assembly off transaxle. Remove 11 oil pump assembly bolts. (Scheme 69) DO NOT remove No. 1 oil pump cover bolt at this time. Remove wiring harness clip. Lift oil pump assembly off control valve body. Set oil pump assembly on it's cover.
3. Remove control valve body bolts. (Scheme 70) Carefully lift fluid pressure manual valve position switch assembly off control valve body. Handle switch assembly carefully, as it is very delicate. Remove control valve body. Remove 2 retainers from valve body. Remove spacer plate with 2 screen/seal assemblies and gaskets from valve body. Remove 6 check balls from valve body. (Scheme 72) Remove case cover pin. Remove 4 check balls from case cover. (Scheme 71)
4. Remove oil pump drive shaft from case cover. Position transaxle so Vehicle Speed Sensor (VSS) is facing up. Remove VSS bolt and VSS. (Scheme 64)

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

OUTPUT SHAFT

1. Remove 4 case extension bolts. Remove case extension and extension seal. (Scheme 64) Leave front differential carrier thrust washer and bearing on carrier. Rotate differential carrier until you can see end of output shaft and pinion shaft is in a 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 through differential side gear. (Scheme 73) Remove differential assembly. Remove snap ring from output shaft.

Scheme 73

FRONT DIFFERENTIAL CARRIER END PLAY CHECK

1. Ensure thrust washer and bearing are still on front differential carrier. Install case extension seal onto case extension (if removed). Install case extension onto transaxle. 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 74) Set dial indicator to zero. 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/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under TRANSAXLE REASSEMBLY.

Scheme 74

MANUAL VALVE LINK & OIL DAM

1. Remove manual shift detent bolt. Remove manual shift detent and spring backing plate. Compress manual valve link spring. Lift spring link off manual valve. (Scheme 75)
2. Position manual valve link so valve will not interfere with case cover removal. Remove oil dam from case. (Scheme 64) Using a 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 75

CASE COVER & GASKETS

Remove indicated case cover bolts. (Scheme 76) Be sure to hold manual valve in place. Lift case cover off case. Remove upper and lower case cover gaskets. (Scheme 103)

Scheme 76

4TH CLUTCH SHAFT & PLATES

Remove 4th clutch backing plate, composition plates and steel plates. Remove 4th clutch shaft. (Scheme 77) Remove drive chain lube scoop. (Scheme 85)

Scheme 77

Drive Chain (Drive Link) Stretch Check

Ensure driven sprocket support assembly and both sprockets are fully seated. Pull drive chain toward case at indicated location. (Scheme 78) Measure distance between case and drive chain. If measurement is.126" (3.2 mm) or more, drive chain may be reused. If measurement is less than.126" (3.2 mm), replace drive chain.

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 master link on drive chain. Link is different color than other links and may be facing up or down toward case. NOTE: Note drive chain direction prior to removal. Drive chain must be installed in same direction during reassembly.
2. Lift drive and driven sprockets with drive chain 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 77)and (Scheme 79). Washers may be stuck to sprockets.

Scheme 78

Scheme 79

DRIVE SPROCKET SUPPORT ASSEMBLY

Insert 2 channel plate bolts (13 mm) into driven sprocket support assembly. (Scheme 80) Grasp bolts and lift support assembly. Remove thrust washer from 2nd clutch housing. Washer may be stuck to support assembly.

Scheme 80

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 81)
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 84)

Scheme 81

REVERSE BAND & REACTION DRUM

Tilt band in order to disengage band from anchor pin in case. Remove reverse band. Lift reverse reaction drum from transaxle case.

INPUT CLUTCH HOUSING END PLAY CHECK

1. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing. Tighten threaded rod until rod is finger tight. Use Remover/Installer to lift input clutch housing. (Scheme 81) Sprag clutch assemblies will also be attached. Install input clutch housing into case. Ensure assembly is down all the way. 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-38385) attached to case extension. (Scheme 82) Using 2 bolts, install End Play Gauge (J-33386) onto case. (Scheme 83) Tighten bolts to securely hold gauge. Tighten aligning tool finger tight in order to eliminate differential carrier end play. (Scheme 82)
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.006" (.15 mm) or more, select next size larger thrust washer and recheck. For input clutch thrust washer identification, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) 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 82

Scheme 83

CASE EXTENSION & DIFFERENTIAL CARRIER

Remove 2 case extension bolts. Remove case extension and remove seal. (Scheme 64) Remove differential carrier thrust washer and thrust bearing. (Scheme 84) Remove differential carrier assembly. 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. Remove differential sun gear shaft. (Scheme 84)

INPUT & REACTION CARRIER

Position transaxle with case cover facing up. Remove input carrier assembly. Remove input carrier and reaction carrier lube dam. Dam may be stuck to input carrier assembly. Remove thrust bearing from reaction carrier. Remove reaction carrier assembly. (Scheme 84)

REACTION SUN GEAR & 2-1 MANUAL BAND

Remove thrust bearing from reaction sun gear. Remove reaction sun gear assembly. Tilt band in order to disengage 2-1 manual band assembly from anchor pin. Remove 2-1 manual band from case. (Scheme 84)

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. Tilt band in order to disengage band from anchor pin. Remove forward band from case. (Scheme 84)

DIFFERENTIAL CARRIER INTERNAL GEAR

Remove thrust washer from differential carrier (final drive) internal gear. Use snap ring remover or large screwdriver to remove differential carrier internal gear retaining ring. Lift differential carrier internal gear out of case by depressing parking pawl to clear case. (Scheme 84)

INPUT SPRAG, SUN GEARS & 3RD ROLLER CLUTCH ASSEMBLIES

Remove input clutch sprag assembly, 3rd roller clutch assembly and input sun gear. Remove reverse reaction drum, input carrier assembly and thrust bearing. (Scheme 84)

PARKING SYSTEM COMPONENTS

1. Remove manual valve link and spring from manual shift detent lever. See «MANUAL VALVE LINK & OIL DAM»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e). Remove manual shift detent lever nut from manual shift shaft. Remove manual shift detent lever and remove parking pawl actuator. (Scheme 86) Use side cutting pliers to remove manual shift shaft pin. DO NOT cut through pin. Protect case with a piece of wood or rubber under pliers when removing pin.
2. Position transaxle with reverse band servo bore facing up. Pull manual shift shaft out of case. Using a 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 86)

Scheme 84

Scheme 85

Scheme 86

Cleaning & Inspection

Clean transaxle case thoroughly with solvent, and then air dry. Inspect for loose, cross-threaded or damaged pipe fittings on transaxle oil cooler. Check for damaged sealing surfaces or for case porosity. Check for stripped or damaged bolt holes. Check for damaged oil passages, snap ring grooves or housing splines. Check for loose, missing or damaged band anchor pins. Ensure torque converter oil seal drain back hole is not plugged. Inspect for loose, plugged or damaged transaxle vent. Check for loose, cross-threaded or damaged oil pressure test hole plug.

Disassembly & Reassembly

If vent is damaged, use channel lock pliers and large screwdriver to remove vent. Use a hammer and punch to install vent. If oil pressure test hole plug was removed, install plug and tighten to 97 INCH lbs. (11 N.m). (Scheme 64)

Inspect bearing for damage and for damaged splines. Remove drive sprocket support and bearing only if damage is visible.

If damage is visible, use slide hammer and bearing puller to remove bearing from drive sprocket support. Remove 4 drive sprocket support bolts and remove drive sprocket. Install NEW bearing using drive handle and bearing installer. (Scheme 87) Install NEW drive sprocket support. Install and tighten drive sprocket support bolts to 18 ft. lbs. (24 N.m).

Scheme 87

Inspection & Reassembly

1. Inspect for worn parking pawl actuator guide or cracked or bent parking pawl actuator. Check for damaged manual shift detent lever. (Scheme 86) Check for worn, stripped or bent shift shaft, or bent or damaged manual valve spring link. Check for bent or kinked manual valve link spring. (Scheme 75) Replace components as necessary.
2. Install shift shaft seal into case using a 9/16" socket and a hammer. 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 rubber mallet.
3. Install shift shaft into case. Align groove for manual shift shaft pin with pin hole in case. Install shaft pin using rubber mallet. Position transaxle with case cover flange facing up. Install parking pawl actuator. Assemble manual shift detent lever onto actuator and onto shift shaft. Install nut on shift shaft and tighten to 23 ft. lbs. (31 N.m).

1. Inspect differential carrier (final drive) internal gear for damaged or worn bushings, plugged lube oil holes, damaged case splines, damaged or worn gear teeth, damaged parking pawl or snap ring. Replace components as necessary.
2. Install differential carrier internal gear into case. Align parking pawl with parking pawl actuator. Using snap ring remover or long screwdriver, install retaining ring into case. (Scheme 84)

Disassembly

1. Use a screwdriver to remove retaining ring from front differential carrier. Remove planetary pinion gear pin, thrust washers, roller bearings, spacer and pinion gear. (Scheme 84) Remove remaining planetary pinions in same manner. Remove differential carrier sun gear thrust bearing. NOTE: Ensure pinion gear is installed in same direction as removed. If gear is installed upside down, noise may result due to change in wear pattern.
2. Place final drive carrier components into an oil pan in order to ensure that roller bearings are not lost. Use a drift pin and hammer to remove differential pinion shaft retaining pin. Remove differential pinion shaft, gears, pinion gear thrust washers, side gears and Bronze side gear thrust washers. (Scheme 84)

1. Inspect differential carrier for damaged or worn teeth, roller bearings, washers or pins on differential planetary pinion gear. Check for damaged or worn teeth or splines on differential carrier sun gear.
2. Check for damaged or worn teeth, splines or thrust washers on differential side gear. Check for damaged or worn teeth, thrust washers or shaft on differential pinion gear. Check for damaged or worn lugs or splines on parking gear. Check for damaged vehicle speed sensor reluctor wheel.
3. Check for damaged differential carrier, sun gear or internal gear thrust bearings. Check for a damaged differential carrier housing. Inspect differential carrier sun gear shaft for damaged or worn splines, cracks at lube oil holes, or damaged or worn bearing journals.
4. Use a feeler gauge to measure differential carrier planetary pinion gear end play. End play should be.009-.025 " (.23-.64 mm). (Scheme 88) If end play is not as specified, repair differential carrier assembly as necessary.

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. 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. Use a drift pin and hammer to install pinion shaft retaining pin into carrier.
2. Apply petroleum jelly to inside of differential carrier planetary pinion gear. For each planetary pinion gear, insert a 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 or 2.84 has 2 rows of 18 rollers. All other gear ratios have 2 rows of 22 rollers.
3. Install differential carrier sun gear thrust bearing into carrier housing. Remove planetary pinion gear pin from it's 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.

Installation

Position transaxle with oil pan flange facing down. Install sun gear shaft into differential carrier. Install internal gear thrust bearing into differential carrier. Ensure bearing is positioned properly. Install parking gear. Install differential carrier sun gear. Step in sun gear must be pointing toward parking gear. Ensure sun gear thrust bearing is installed into differential carrier. Install differential carrier into case. (Scheme 84)

Scheme 88

VEHICLE SPEED SENSOR RELUCTOR WHEEL

Note. DO NOT remove reluctor wheel if it is not damaged.

To remove reluctor wheel, install flat metal stock onto carrier. 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. To reassemble, heat reluctor wheel slightly. Using plastic hammer, install reluctor wheel onto carrier by tapping evenly around reluctor wheel edge. (Scheme 84)

Inspect case extension for damaged or porous sealing surfaces, damaged bolt holes, worn or damaged differential carrier bushing or output shaft bearing. Repair as necessary.

Install selective thrust washer and thrust bearing onto differential carrier. Install seal onto case extension. Install case extension onto transaxle case. Install and tighten bolts until extension is flush to case.

1. Inspect forward band for damaged or severely worn friction material. Check for damaged apply or anchor pin. Inspect differential carrier internal gear thrust washer for damage. Replace components as necessary.
2. Position transaxle case with flange for case cover facing up. Install differential carrier internal gear thrust washer into case. Install forward band into case. Locate band onto forward band anchor pin. Position band apply pin in case opening.

Using a 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 84)

Inspect 1-2 support drum for scored or burned contact surface from 2-1 manual band. Check for damaged or worn forward drum bushing. Check for damaged or worn 1-2 support roller clutch inner race. Check for damaged or worn 1-2 roller clutch assembly. Inspect for damaged thrust bearing. Replace components as necessary.

Install 1-2 roller clutch assembly into 1-2 support drum. Note position of cage assembly to inner race. (Scheme 89) 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 90) 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 89

Scheme 90

Inspect 2-1 manual band for cracked, separated or burnt friction material. Inspect for cracks around apply lugs. Squeeze 2-1 manual band and install assembly into transaxle case. Position band on anchor pin.

Inspect reaction sun gear and drum for worn or scored bushings. Check for damaged reaction sun gear teeth. Check band apply area of drum for discoloration or wear. Inspect welds connecting sun gear to drum for voids or cracks. Check for worn or damaged 1-2 support outer race. Install reaction sun gear and drum into case. (Scheme 84) Ensure lugs engage with 1-2 support roller clutch inner race.

1. Use feeler gauge to check for excessive pinion gear end play in input carrier and reaction carrier assemblies. End play should be.009-.030" (.23-.77 mm). If end play is not as specified, replace appropriate component. (Scheme 91)
2. Inspect thrust bearings for damaged cage, or damaged or missing rollers. Inspect reaction carrier for damaged pinion teeth or internal gear teeth. Inspect input carrier for damaged pinion or spline teeth. Replace components as necessary.

Note. Use petroleum jelly to hold components in place and as an assembly lube.

Install thrust bearing onto reaction carrier. Install reaction carrier into transaxle case and rotate carrier so that pinions engage reaction sun gear. Install thrust bearing onto input carrier. Install lube dam into reaction carrier. Insert input carrier into transaxle case and rotate carrier so that pinions engage reaction carrier internal gear. (Scheme 84)

Scheme 91

Inspect reverse reaction drum for cracks, damaged splines or distortion. (Scheme 84) Replace drum if necessary. Install reverse reaction drum into transaxle case and engage drum onto input carrier splines.

1. Remove input and 3rd sprag clutch assemblies from input clutch housing. (Scheme 84)and (Scheme 85). Remove and discard spiral lock retaining ring from outer race retainer of clutch sprag. Remove 3rd clutch sprag and input clutch sprag assemblies from inner race and retainer. Remove inner race and retainer. Remove input sun gear spacer from input sun gear. (Scheme 84)
2. Remove 3rd clutch sprag retainer. Remove end bearing and center bearing from sprag outer races. DO NOT disassemble sprag components. Remove sprag components from outer races.

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. Replace components as necessary.

1. Position input clutch sprag on a flat surface with lube dam side facing up. Insert end bearing for input and 3rd clutch sprag into outer race. Insert input sprag into outer race. (Scheme 92)
2. Position 3rd clutch sprag outer race on flat surface with lube dam side facing down. Lip on 3rd sprag must be facing up. Install center bearing into 3rd clutch. Lip on sprag cage must be facing up. Install 3rd sprag into 3rd clutch outer race. Insert end bearing into 3rd clutch outer race. (Scheme 93)
3. Install input sprag onto inner race of input and 3rd clutch sprag. Install 3rd sprag onto inner race. Install retainer onto 3rd clutch sprag outer race. NOTE: Use new retaining rings. DO NOT attempt to reinstall old retaining rings. Ensure spiral lock retaining ring is seated in groove on inner race. Tabs and slots on retaining ring must lock.
4. Attach retaining ring installer to arbor press. Use press and small flat blade screwdriver to 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 94)

Input & 3rd Sprag Clutches Functional Check

Hold input sun gear stationary. The 3rd sprag clutch outer race should rotate only in counterclockwise direction and not in opposite direction. Input sprag clutch outer race should rotate in clockwise direction and not in opposite direction. (Scheme 95)

Scheme 92

Scheme 93

Scheme 94

Scheme 95

1. Using a flat-bladed 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.
2. Using a flat-bladed screwdriver, remove retaining ring from input clutch housing. Remove 3rd clutch backing plate. Remove 3rd clutch plate assembly. Remove 3rd clutch waved plate. Remove input shaft thrust bearing. (Scheme 85)
3. Using spring compressor and adapter, compress 3rd clutch spring assembly. Using snap ring pliers, remove retaining ring from 3rd clutch housing. DO NOT over expand retaining ring during removal. Remove adapter, spring compressor and 3rd clutch spring assembly. Remove 3rd clutch piston and seal.
4. Using spring compressor, compress 3rd clutch piston housing. Using snap ring pliers, remove retaining ring from 3rd clutch housing. DO NOT over expand retaining ring during removal. Remove spring compressor. Remove 3rd clutch piston housing, spring assembly and piston. Remove input clutch piston outer seal. (Scheme 85)
5. Remove 3rd clutch piston inner seal, housing "O" ring seal and input clutch piston inner seal. Cut and remove oil seal rings. DO NOT damage grooves on shaft when oil seal ring is removed.

1. Inspect input clutch housing for plugged fluid feed passages, worn or damaged splines, or input shaft bushing wear. Check seal ring groove for nicks or burrs. Check for cracks or blocked fluid passages in input shaft. Inspect for damage or wear to thrust bearing, located in input clutch housing.
2. With check ball in it's seated position in transaxle fluid, inspect for leaks. Inspect input clutch piston for cracks or damage to seal grooves. Check 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. Check input shaft thrust bearing for damage or wear. Replace components as necessary.

1. Lubricate NEW input clutch piston inner seal with transaxle fluid. Using appropriate piston seal protector, install inner seal onto piston. Install NEW "O" ring seal in 3rd clutch housing. Lubricate NEW 3rd clutch piston inner seal with transaxle fluid. Using appropriate piston seal protector, install inner seal onto piston.
2. Lubricate NEW input clutch piston outer seal with transaxle fluid. Using appropriate piston seal protector, install outer seal onto piston. Install input clutch piston into input clutch housing. Install input clutch spring retainer into input housing assembly. Install 3rd clutch piston housing into input housing assembly. Using spring compressor and snap ring pliers, install retaining ring in 3rd clutch housing. (Scheme 85) Remove spring compressor.
3. Lubricate NEW 3rd clutch piston assembly and install into input housing. Install 3rd clutch spring assembly into input housing. Using spring compressor, adapter and snap ring pliers, install 3rd clutch housing retaining ring. Insert 3rd clutch waved plate into input housing.
4. 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 the word UP facing up. Install retaining ring into input housing.
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. Start with first input clutch steel plate. Assemble composition plates alternately between steel plates. Install input clutch backing plate with tapered teeth side facing up. Install retaining ring on input clutch housing. Install input shaft thrust bearing into input clutch housing. (Scheme 96)

Input Clutch & 3rd Clutch Functional Check

Using a rubber tipped air nozzle, apply a maximum of 20 psi (138 kPa) at indicated fluid passage holes. (Scheme 97) Ensure input clutch and 3rd clutch apply. If clutch does not apply, recheck component reassembly.

Scheme 96

Scheme 97

INPUT CLUTCH HOUSING CHECK BALL VALVE

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

Using a 1/4" drift and hammer, remove check ball valve from input clutch housing. To reassemble, use a 3/8" drift and hammer to install check ball valve into input clutch housing. (Scheme 98)

Scheme 98

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 them one at a time on Seal Protector (J-34741-1). (Scheme 99)
2. Quickly slide each seal into ring groove when protector is in position. Use Seal Driver (J-34741-2) to 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 99

Use a small screwdriver to 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.

Using flat-blade screwdriver, remove retaining ring from 2nd clutch housing. Remove backing plate. (Scheme 85) Remove composition plates, steel plates and apply plate. Remove waved plate. Remove retaining ring. Remove 2nd clutch spring assembly and 2nd clutch piston.

1. Check for leaking or damaged check ball valve in 2nd clutch housing. Turn housing in order to seat check ball valve. Use transaxle fluid in order to check for leaks. Check for scored or worn bushings. Check for discolored band surface or wear on drum caused by excessive heat. Check for flatness of band surface on drum.
2. Check for damaged reverse reaction drum splines. 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. Inspect apply ring and spring assembly for damage. Inspect piston and piston seals for damage. Inspect 2nd clutch housing for damaged inner piston seal. Inspect housing for warpage.

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.
2. Install 2nd clutch spring assembly into housing. Install retaining ring. Install waved plate. Install apply plate into 2nd clutch housing with marking DN or DOWN toward piston. Install composition plates and steel plates, starting with composition plate and alternating each plate. Install backing plate and retaining ring. (Scheme 85)

If check ball valve does not leak, DO NOT replace check ball valve. Remove check ball valve from housing using a 1/4" drift and hammer. Tap in NEW check ball assembly using same drift and hammer.

Inspect reverse band for cracks, scoring, lining separation or wear on fiber material. Inspect apply lug for cracks. Replace components as necessary. Install reverse band into case with band end aligned on anchor pin in transaxle case.

Use appropriate spring compressor to compress 4th clutch spring assembly. Remove snap ring from driven sprocket support assembly. (Scheme 100) Remove spring compressor, spring assembly and 4th clutch piston from driven sprocket support assembly. Remove outer seal from piston. Remove inner seal from driven sprocket support assembly hub. Remove oil seal rings and 4-lobed ring seal from driven sprocket support assembly. (Scheme 85)

1. Check for worn or cut oil seal rings. Check for rolled or cut 2nd clutch housing oil seal rings. Check for damage to piston seal surface in driven sprocket support assembly. Check for blocked or porous fluid passages in driven sprocket support assembly.
2. Inspect 4th clutch piston for damage. Check thrust washer from 2nd clutch housing for cracks or distortion. Check 4th clutch spring assembly for distorted or missing springs. Check driven sprocket bearing assembly for foreign material and missing, flat or damaged rollers. Replace Teflon oil seal rings if rings are cut or damaged, or if complete overhaul is being performed. Check all seal ring grooves for debris, burrs or damage.

1. Lubricate NEW inner and outer seal with transaxle fluid prior to installation. Install outer seal on 4th clutch piston. Install inner seal for 4th clutch piston onto driven sprocket support hub. (Scheme 101)
2. Install 4th clutch piston into driven sprocket support and align components. Install 4th clutch spring assembly into piston. Using spring compressor, compress spring assembly and install snap ring. (Scheme 100) Lubricate NEW oil seal rings for 2nd clutch housing if they are being replaced. Install rings onto driven sprocket support hub.

2nd & 4th Clutch Functional Check

1. Apply 20 psi (138 kPa) of compressed air to feed holes marked 2 and 4, and listen for 2nd and 4th clutch application. (Scheme 102) Hold pressure for 5 seconds. If clutches do not apply and hold, disassemble driven sprocket support components.
2. 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.

Use petroleum jelly to secure housing thrust washer for 2nd clutch to driven sprocket support assembly. Finger tighten 2 channel plate bolts (13 mm) into driven sprocket support assembly. Using bolts, lift driven sprocket support into transaxle case. (Scheme 80) Top of support should be flush with case. If support is not flush with case, one of the clutches is not fully seated.

Scheme 100

Scheme 101

Scheme 102

Using appropriate bearing remover and hammer, drive driven sprocket support bearing from support. To reassemble, position driven sprocket support bearing assembly so markings on edge are facing up. Using appropriate bearing installer and hammer, seat bearing flush to or below support hub.

1. Ensure selective thrust washer and thrust bearing assembly for input clutch housing are in place. Use a small screwdriver to align 2nd clutch teeth so they slide onto 2nd clutch hub of input clutch housing assembly. Install 2nd clutch housing assembly onto 2nd clutch hub of input clutch housing assembly. (Scheme 85)
2. Install Final Drive/Clutch Remover/Installer (J-33381-A) into 2nd clutch housing. (Scheme 81) Tighten threaded rod until rod is finger tight. Use remover/installer to lift 2nd clutch housing and input clutch assembly. Sprag clutch assemblies will also be attached. Install assembly into transaxle case. Ensure assembly is all the way down. Confirm that top of 2nd clutch is flush or slightly below top of reverse band.

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 77)

1. Inspect sprocket teeth for wear or chips. Ensure teeth size are uniform. Check for stripped or damaged splines. Check bearing surface for damage. Check thrust washers for wear or cracks. Replace components as necessary.
2. Insert turbine shaft into drive sprocket and attach retaining ring. Install appropriate seal installer onto turbine shaft. Coat shaft with petroleum jelly. Slide turbine shaft seals into position. Use appropriate seal sizer to size seals.

Inspect drive chain assembly for cracks, binding links or damage. Check input speed sensor reluctor wheel for damaged teeth, worn or damaged thrust surface or damaged or missing locating pins.

1. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. Assemble drive and driven sprockets into drive chain assembly as follows: If old drive chain is being reinstalled, assemble drive chain and sprockets with master link (Bronze) facing in same direction as removed. See «DRIVE & DRIVEN SPROCKETS»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under TRANSAXLE DISASSEMBLY. If a NEW drive chain assembly is being installed, assemble drive chain and sprockets with master link facing upward.
2. Install drive chain 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. Install thrust washer onto reluctor wheel. (Scheme 77) Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See «DRIVE & DRIVEN SPROCKETS»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) under TRANSAXLE DISASSEMBLY.

1. Inspect 4th clutch assembly steel plates for wear or damage. Check composition plates for peened splines, flaking or wear. Check 4th clutch shaft assembly for cut or worn 4th clutch plate splines. Check for damage or wear to shaft bushing. Inspect for damaged bushing journal. Inspect input sun gear for stripped splines. Check for cracks or damage to hub shaft. Replace components as necessary.
2. Insert 4th clutch shaft into transaxle case through driven sprocket. (Scheme 77) Shaft must fully seat into input sun gear. Install drive chain lube scoop into case. Install a steel 4th clutch plate into driven sprocket support with machined side toward sprocket. Install remaining 4th clutch plates, alternating between composition plates and steel plates. Clutch plates should align in driven sprocket support. Install 4th clutch reaction plate onto driven sprocket support.

CASE COVER COMPONENTS

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

Remove manual valve. Remove cylinder and "O" ring seal for 3-4 accumulator piston. Remove outer and inner spring. Remove pin for 3-4 accumulator piston. (Scheme 103)

1. Inspect 3-4 accumulator piston cylinder for porosity, scored pin or nicked or grooved piston sleeve. Check piston pin for scoring and free movement in piston bore. Check springs for distorted or broken coils. Inspect piston cylinder for porosity or cracks. Check for rough or scored seal surface, or cut seal. Inspect check ball, spring and bore plug.
2. DO NOT remove blow-off check balls unless they are 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 orificed 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. Check case cover for porosity, interconnected fluid passages, cracks or rough machined surfaces. Check input speed sensor for damaged or missing magnet. Check for damaged housing, bent or missing electrical terminals, or damaged speed sensor clip.

Bearing Replacement

Place case cover on clean flat surface with spacer plate mating surface down. Using driver handle, bearing remover and hammer, drive out bearing from case cover. To install, drive bearing into case cover until bearing installer stops against case cover.

Install NEW seal onto 3-4 accumulator piston. Install 3-4 accumulator piston cylinder into case cover. Install NEW seal onto accumulator piston cylinder. Install springs into 3-4 accumulator piston cylinder. Use a slight twisting motion in order to insert accumulator piston cylinder into case cover. Insert 3-4 accumulator piston pin through front of case cover and into piston. Assemble manual valve and install valve assembly into case cover.

Scheme 103

Using Seal Remover (J-23129) and slide hammer, remove left oil seal from case cover, or right oil seal from case extension. To install, use appropriate seal installer and hammer. Lubricate oil seal lip with transaxle fluid. Ensure seal was not damaged during installation.

Note. DO NOT use any type of adhesive or sealer when assembling gaskets. Petroleum jelly may be used during assembly.

Install upper and lower gaskets for transaxle case cover. (Scheme 103) Ensure manual valve is held in place and assemble case cover onto pins in case. Finger tighten all transaxle case cover bolts. (Scheme 76) Tighten bolts to specification. DO NOT use an impact wrench to tighten bolts.

Install oil dam into case. Install manual valve link and spring into manual shift detent lever. Pull back manual valve spring and connect manual valve spring link to manual valve. (Scheme 75) Install manual shift detent, backing plate and bolt. (Scheme 86) Tighten bolt to 97 INCH lbs. (11 N.m). Install input speed sensor into case cover. Install sensor clip into case cover.

Inspect output shaft for damaged bushing journals, stripped splines or retaining ring groove damage. (Scheme 77) Rotate transaxle so oil pan flanges face down. Ensure differential thrust washer and thrust bearing are either on differential carrier assembly or in case extension. Remove transaxle case extension bolts. Remove case extension. Install output shaft. To complete reassembly, install case extension.

Check for damaged connector, cracked housing, signs of rotor damage or cuts or nicks on seal. Install NEW seal over speed sensor. Install speed sensor into case extension. (Scheme 64) Install bolt and tighten to 97 INCH lbs. (11 N.m).

Thoroughly clean and air dry control valve body. Remove each valve train, noting location of each component. Cover bores when removing retainers, because some valves are under spring pressure. Remove retainers with a small screwdriver. Lay valves, springs and bushings on a clean surface in the order removed. (Scheme 104)and (Scheme 105).

Clean valves, springs and bushings in solvent. DO NOT use shop rags to clean valve body components. Inspect valves and bushings for scoring, nicks and scratches. Inspect springs for damaged or distorted coils. Inspect valve body casting for porosity, interconnected oil passages and damaged machined surfaces. Inspect fluid pressure manual position switch assembly for damaged electrical connectors, seals, switch membranes or debris.

To reassemble valve body components, reverse disassembly procedure. Ensure all components are installed in original locations.

Scheme 104

Scheme 105

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 one at a time for excessive peening. Place a check ball on each seat. Use a flashlight to look for visible light between check ball and seat. (Scheme 106) If light is visible between check ball and seat, replace spacer plate.
2. Install 4 check balls into case cover. (Scheme 71) Use petroleum jelly to hold check balls in position. Install 2 large check balls and 4 small check balls into control valve body. (Scheme 107) Use petroleum jelly to hold check balls in control valve body.
3. Install solenoid screen/seal assemblies into spacer plate. Install case cover guide pin into case cover. Install lower spacer plate gasket, spacer plate and upper spacer plate gasket onto control valve body. Install bolts to hold spacer plate and gaskets onto control valve body. (Scheme 72)
4. 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. Install fluid pressure manual valve position switch onto control valve body.
5. Install control valve body bolts. (Scheme 70) 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 bolts to specification. (Scheme 70)

Scheme 106

Scheme 107

Clean and air dry oil pump. Remove oil pump cover bolts. Remove oil pump cover. Remove vane rings, vanes and rotor. Remove oil seal ring and slide "O" ring seal. Remove outer and inner oil pump prime springs. Remove slide, slide seal support and slide seal. Remove pivot pin. Remove outlet screen. (Scheme 108)

1. Inspect pump body for porosity, interconnected oil passages, or damaged inner pump area surface or machine facing. Check slide, springs, rotor and vanes for damage. Inspect slide seal, slide support and seals for damage. (Scheme 108)
2. Measure undamaged area of rotor, vane or slide to check for proper size. See «OIL PUMP COMPONENT THICKNESS»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. (Scheme 109) Ensure replacement parts are matched to fit within specification.

Note. Laser marks on oil pump body indicate size of selective parts which were used in assembly. If correct parts are not selected for replacement, damage to oil pump and transaxle will occur. Oil pump components are matched sets. DO NOT mix old and new parts.

OIL PUMP COMPONENT THICKNESS

Install oil pump outlet screen. Install vane rings onto pump pocket. Install pump slide into pump body. Install seal and support into slide. Install inner priming spring into outer priming spring. Install both springs into pump body. Install "O" ring and seal ring onto slide. (Scheme 108) Install rotor into pump body. Install vanes into rotor slots, ensuring vanes are flush with top of rotor. Install pump cover onto body using cover bolts. Tighten bolts to 70 INCH lbs. (8 N.m).

Install oil pump assembly onto control valve body. Install 11 bolts in specified locations. (Scheme 69) Tighten bolts to 106 INCH lbs. (12 N.m).

Scheme 108

Scheme 109

Inspect wiring harness for cut or pinched wires, cut wire insulation, bent or broken electrical connectors or damaged terminals. Position wire harness assembly onto control valve body and oil pump. Mate each connector into its respective electrical component and engage locking tabs. (Scheme 68) Secure harness conduit into retaining clip on oil pump cover. Install A/T fluid temperature sensor into retaining clip.

CASE SIDE COVER

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

1. Inspect case side cover for damaged or porous gasket sealing surfaces, or damaged or stripped bolt holes. Inspect case side cover gasket and channel plate seal for damage. Gasket and seal can be reused if not damaged.
2. Install channel plate seal to cover. (Scheme 72) Use petroleum jelly to hold seal in position. Install cover gasket and case side cover onto transaxle case. Ensure gasket, seal and electrical connectors are positioned correctly. Install 2 flange bolts at 3 o'clock and 9 o'clock positions. (Scheme 67) These bolts locate cover and gasket to transaxle case. Install remaining bolts in specified locations. Tighten all bolts to 18 ft. lbs. (24 N.m).

THERMO ELEMENT ADJUSTMENT

If thermo element replacement is necessary, remove retainers, pins and thermo element. Remove plate element. For NEW element, set thermo pin height with Height Gauge (J-34094-A). (Scheme 110) 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 110

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. Use a small screwdriver to remove retaining ring from servo piston pin. Remove servo piston, cushion spring and spring retainer from servo piston pin. (Scheme 66)

1. Check for damaged, worn or porous servo piston cylinder. Check for damaged, worn or porous servo piston. Check for damaged or worn servo piston pin. Check for broken or damaged servo piston spring or cushion spring. Check for damaged or plugged servo exhaust screen. Check for damaged servo cover gasket, servo piston seal or servo piston cylinder "O" ring seal.
2. Install servo piston spring retainer, cushion spring and servo piston to servo piston pin. Install servo piston pin retaining ring. Install servo piston seal onto piston. Lubricate seal with transaxle fluid. Install servo exhaust screen and servo piston cylinder "O" ring seal onto cylinder. Lubricate "O" ring seal with transaxle fluid. Attach servo piston spring to piston assembly. Install servo piston assembly into cylinder assembly and set assemblies aside.

1. Remove 7 accumulator cover bolts from accumulator assembly. Dissemble accumulator cover and spacer plate from accumulator housing. Disassemble 1-2 and 2-3 accumulator pistons, piston pins, inner and outer springs and cushion springs from accumulator housing. (Scheme 66) Remove piston oil seal rings from 1-2 and 2-3 accumulator pistons.
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 66)

1. Inspect for damaged lube and servo oil pipe holes in accumulator cover. Check for damaged, improperly machined or porous accumulator cover or housing. Check for bent or damaged accumulator spacer plate. Check for damaged accumulator cover gaskets. Check for stripped or damaged bolt holes in accumulator housing. Check for leaking, loose or missing cup plugs in accumulator housing.
2. Inspect for broken or collapsed piston springs (inner, outer or cushion). Check for bent or worn accumulator piston pins. Check for damaged, worn or porous accumulator pistons. Check for damaged accumulator piston seals. Replace components as necessary.
3. Check for damaged lube and servo oil pipe holes in servo cover. Check for damaged, improperly machined of porous servo cover. Check for bent, plugged or damaged lube and servo oil pipes. Check for plugged or damaged lube oil hose. Check for damaged hose clamps, lube oil pipe retainer or missing lube oil pipe washer.

1. Install 1-2 and 2-3 accumulator piston oil seal ring onto appropriate accumulator piston. Lubricate oil seal ring with transaxle fluid. Assemble 1-2 and 2-3 piston pin and piston. Assemble 1-2 and 2-3 accumulator piston springs and piston assembly into accumulator housing. (Scheme 66)
2. Assemble accumulator spacer plate and cover onto accumulator housing. Install 7 accumulator bolts and tighten to 97 INCH lbs. (11 N.m). Assemble lube oil pipe, oil hose, hose clamps, pipe retainer and pipe with washer. (Scheme 66)
3. Assemble 2-1 manual band servo and forward band servo oil pipes into accumulator assembly. Assemble 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.

Install cover gasket to 2-1 manual band servo into case. Lubricate gasket with transaxle fluid. Install 2-1 manual band servo assembly into case. Ensure servo piston pin engages band. Install accumulator and cover assembly to 2-1 manual band servo into case. Install lube oil pipe into case at lube hole for differential carrier internal gear. Lock lube oil pipe retainer into case. Install 3 manual cover bolts for 2-1 manual band servo. Tighten bolts to 18 ft. lbs. (25 N.m). Install 4 accumulator cover bolts and tighten bolts to 97 INCH lbs. (11 N.m). (Scheme 65)

1. Check for damaged sealing surface. Check for dented or cracked 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 64)
2. Position transaxle with oil pan sealing surface facing up. Using a socket and plastic mallet, gently tap oil filter seal into case. Gently tap oil filter into case. Install oil pan gasket onto transaxle case. Install oil pan and 20 oil pan bolts. Tighten bolts to 10 ft. lbs. (14 N.m).

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 64)

1. Inspect for damaged, worn or porous servo piston. Check for damaged servo piston seal or servo cover seal. Check for broken or collapsed servo piston spring or cushion spring. Check for damaged or worn servo piston pin or servo cover. Replace components as necessary.
2. Assemble servo piston, servo piston cushion spring, 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 64)
3. Position transaxle with oil pan facing up. Install servo cover seal onto servo cover. Assemble servo assembly into servo cover. Pivot servo into cover to prevent piston seal from being damaged. Install servo and cover into case.
4. Using a long screwdriver, pry against bench and compress forward band servo assembly. Hold servo assembly compressed and install 3 forward band servo cover bolts. Tighten bolts to 89 INCH lbs. (10 N.m). Remove screwdriver.

Disassemble reverse band servo piston 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.

1. Inspect for damaged, worn or porous servo piston. Check for damaged servo piston seal or servo cover seal. Check for broken or collapsed servo piston spring or cushion spring. Check for damaged or worn servo piston pin or servo cover. Replace components as necessary.
2. Assemble servo piston, servo piston cushion spring, 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 64)
3. Position transaxle with oil pan facing up. Install servo cover seal onto servo cover. Install servo and cover assembly into case. Using a long screwdriver, pry against transaxle holding fixture and compress reverse band servo cover. Hold servo assembly compressed and install retaining ring. Remove screwdriver.

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 (Scheme 111)- (Scheme 115).

1. Install sun gear shaft, forward band, 2-1 manual band, reaction sun gear and reverse reaction. Ensure 2-1 manual band anchor pins engage band, and 2-1 manual band assembly stop is in place.
2. Check front differential carrier end play. See «FRONT DIFFERENTIAL CARRIER END PLAY CHECK»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__front-differential-carrier-end-play-check) under TRANSAXLE DISASSEMBLY. (Scheme 74) Install appropriate thrust washer onto input shaft and hold in position with petroleum jelly. See «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates.
3. 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.
4. Check input clutch housing end play. See «INPUT CLUTCH HOUSING END PLAY CHECK»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e__input-clutch-housing-end-play-check) under TRANSAXLE DISASSEMBLY. (Scheme 83) 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/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) table. CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES Washer ID No. Color Thickness - In. (mm) 1 Orange.055-.059 (1.40-1.50) 2 White.059-.063 (1.50-1.60) 3 Blue.063-.067 (1.60-1.70) 4 Pink.067-.071 (1.70-1.80) 5 Brown.071-.075 (1.80-1.90) 6 Green.075-.079 (1.90-2.00) 7 Black.079-.083 (2.00-2.10) 8 Purple.083-.087 (2.10-2.20) 9 Purple/White.087-.091 (2.20-2.30) 10 Purple/Blue.091-.094 (2.30-2.40) 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)
5. Install reverse reaction plate and thrust washer. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub, and clutch housing must engage reverse reaction drum splines.
6. Install reverse band into case, locating band on anchor pins. Install thrust washer to driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case, ensuring support lube hole aligns with hole in bottom of case. Install output shaft into case. Install snap ring onto output shaft. (Scheme 73)
7. Coat Seal Installer (J-29569-1 and J-29829-1) with petroleum jelly, and place seal installer over turbine shaft. Slide oil ring seals into position. Using Seal Sizer (J-29569-2 and J-29829-1), size seals by gently twisting sizer over seal.
8. Install thrust washer onto drive sprocket, and hold washer in position with petroleum jelly. Install sprockets and drive chain onto case. If original drive chain is reused, ensure drive chain is installed in same direction as removed. Check drive chain stretch. See DRIVE CHAIN (DRIVE LINK) STRETCH CHECK under «DRIVE & DRIVEN SPROCKETS»(/buick/park-avenue/ii-1996-2002/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t65-e) in TRANSAXLE DISASSEMBLY. If NEW drive chain is installed, install with master link facing upward.
9. Install thrust washer onto driven sprocket and retain with petroleum jelly. Insert 4th clutch hub and shaft through driven sprocket, and install 4th clutch plates starting with steel plate. (Scheme 77)
10. If necessary, pry out axle seal, and tap NEW seal into place. Install pistons and pins into case cover. Install springs into case cover. Install case cover gaskets. Install thrust washer onto case cover. (Scheme 103)
11. Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch plates. (Scheme 77) Install and tighten case cover bolts. (Scheme 76) Install 4 check balls in case cover, using petroleum jelly to retain check balls. (Scheme 71)
12. Install NEW case cover/spacer plate gasket onto case cover using alignment pins. Install spacer plate onto gasket. Install NEW control valve body/spacer plate gasket onto spacer plate. (Scheme 72)
13. Install oil pump drive shaft. Install 6 check balls into control valve body assembly. Use petroleum jelly to retain check balls in place. (Scheme 107)
14. Install control valve body assembly onto case cover using alignment pins. (Scheme 70)and (Scheme 72). Install control valve body bolts and tighten to specification. (Scheme 70) Install servo pipes into control valve body using retainer and bolt. Install oil pump onto control valve body assembly. Install oil pump bolts. (Scheme 69)
15. Install gasket and channel plate seal onto transaxle case and case side cover. (Scheme 72) Install electronic components and wiring harness. Ensure wire connectors are installed in correct locations. (Scheme 68) Install case side cover. (Scheme 67)
16. Install accumulator piston pins into case. Install accumulator springs into case. Install accumulator cover, pipes and retainer onto case as an assembly. Install lube oil pipe retainer onto lube oil pipe. Install oil hose and clamps onto lube oil pipe. Install lube oil pipe into accumulator housing. Ensure lube oil pipe and 2-1 manual servo pipe are installed correctly.
17. The 2-1 manual servo pipe should be installed in accumulator housing center hole, and lube oil pipe should be installed in right side hole. (Scheme 66) Forward servo pipe cannot be installed in wrong hole due to a larger pipe diameter.
18. Ensure lube oil pipe is installed into differential carrier internal gear. Install NEW oil filter seal, oil filter and pan gasket into case. Install oil pan. (Scheme 64) Install forward and reverse servo return springs into proper servo bore. Assemble each servo and then install into case. Install NEW oil seal ring onto each servo cover.
19. Install forward and reverse servo covers into case. Install retaining ring and cover bolts. (Scheme 64) Install vehicle speed sensor. Use Converter Holding Strap (J-21366) to hold torque converter in place during transaxle installation.

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

See also:
• FLUID CAPACITIES
• CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR (VSS)
• ROAD TEST
• LINE PRESSURE TEST
• SYMPTOM DIAGNOSIS
• FRONT DIFFERENTIAL CARRIER END PLAY CHECK
• INPUT CLUTCH HOUSING END PLAY CHECK