Automatic Transmission - 4l60-e/4l65-e - Overhaul & Testing Cadillac Escalade GMT800

APPLICATION

AUTOMATIC TRANSMISSION APPLICATIONS

IDENTIFICATION

Vehicle model is identified by 4th character (cars), or 5th character (trucks) of Vehicle Identification Number (VIN). VIN is stamped on metal pad on top of left end of instrument panel, near windshield. See MODEL IDENTIFICATION table.

The Hydra-Matic 4L60-E transmission can be identified by a letter code contained in identification number. Identification number is stamped on transmission case above oil pan rail on right rear side, or to rear of oil pan. (Scheme 104) Identification number contains information which must be used when ordering replacement parts. Transmission RPO code is M30.

MODEL IDENTIFICATION

Scheme 104

GEAR RATIOS

TRANSMISSION GEAR RATIOS

DESCRIPTION & OPERATION

The Hydra-Matic 4L60-E is a fully automatic transmission consisting of a 3-element hydraulic torque converter with a Torque Converter Clutch (TCC). The 4-speed transmission is equipped with 2 planetary gear sets, 5 multiple-disc clutches, one sprag clutch, one roller clutch and a 2-4 band. (Scheme 105)

A hydraulic system, pressurized by a variable capacity vane type oil pump, provides pressure required to operate friction elements and automatic controls. The 4L60-E contains electronic solenoids that control hydraulic operations. A Powertrain Control Module (PCM) or Vehicle Control Module (VCM) receives input signals from Vehicle Speed Sensor (VSS), Throttle Position (TP) sensor and Transmission Fluid Pressure (TFP) manual valve position switch which incorporates the fluid temperature sensor. These input signals help the PCM/VCM determine when to switch 2 shift solenoids, 3-2 downshift solenoid, and/or TCC solenoid on or off. PCM/VCM can control line pressure through pressure control solenoid (force motor).

Line pressure control system compensates for normal wear of transmission components during upshifts in order to maintain optimal shift quality during life of transmission. PCM/VCM uses "adaptive learning" to maintain acceptable upshift times by adjusting line pressure. PCM/VCM compares actual "acceptable" shift time to calibrated desired shift time and calculates difference. An "acceptable" shift is considered valid if no inconsistent vehicle operations (A/C compressor cycling or extreme throttle changes) occurred during upshift. Line pressure is either increased or decreased depending on duration of upshift time.

Scheme 105

LUBRICATION

Note. For additional information, see appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSAXLE/TRANSMISSIONS.

Note. The 4L60-E transmission used on Corvette is not equipped with a dipstick.

TROUBLE SHOOTING

Note. For testing and diagnostic procedures of electronic components, see HYDRA-MATIC 4L60-E ELECTRONIC CONTROLS article.

Inspection

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 a finger 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.

Torque converter must be replaced for any of the following reasons

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

Torque Converter End Play Check

1. Inspect torque converter for hub scoring, cracks or weld area cracks before checking end play. Install End Play Checking Tool (J-35138) on torque converter. (Scheme 106)
2. Note end play of torque converter. End play must be within specification. See «TORQUE CONVERTER END PLAY SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. Replace torque converter if end play is not within specification or damage to hub area exists.

TORQUE CONVERTER END PLAY SPECIFICATIONS

Scheme 106

CONVERTER HOUSING

Mount transmission on bench using Holding Fixture (J-8763-02). Remove torque converter. Using 50 mm Torx Plus Bit (J-41510), remove converter housing bolts, and remove converter housing. (Scheme 107)

Removing Torque Converter. Scheme 107

2-4 SERVO ASSEMBLY

Install Servo Cover Compressor (J-29714-A) on oil pan. (Scheme 109) Compress servo cover. Remove retaining ring, servo cover and "O" ring. Remove 2-4 servo assembly. (Scheme 108)

Removing Servo Assembly. Scheme 108

Scheme 109

EXTENSION HOUSING

Remove Vehicle Speed Sensor (VSS) retaining bolt. Remove speed sensor assembly and "O" ring. (Scheme 129) Remove extension housing and seal. Remove output shaft sleeve and "O" ring (if equipped). Remove speed sensor rotor from output shaft (if necessary). Install Gear Puller (J-21427-01) and Adapter (J-8433) on rotor. Pull rotor from output shaft. Install Output Shaft Support Fixture (J-29837-A) on output shaft. (Scheme 110)

Scheme 110

VALVE BODY, 1-2 & 3-4 ACCUMULATORS

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

1. Remove transmission oil pan. Remove oil filter and "O" ring. Ensure "O" ring is removed from transmission case. Remove electrical connectors from switches and solenoids, and mark for reassembly reference. (Scheme 111)Remove TCC PWM solenoid retainer clip. Remove solenoid. (Scheme 112)
2. Remove TCC solenoid bolts. (Scheme 113) Remove valve body bolts securing wiring harness. Remove TCC solenoid and allow wiring harness to hang over side of case. (Scheme 114) Remove transmission fluid pressure manual valve position switch. (Scheme 115) Remove detent spring bolt. Remove detent spring. (Scheme 116) Remove remaining valve body bolts. Note length and location of bolts for installation reference. (Scheme 117)
3. Note direction of manual valve link. Remove manual valve link from manual valve at valve body. (Scheme 118) Remove valve body. Note location of check balls on valve body. (Scheme 119)
4. Carefully remove accumulator cover retaining bolts, 1-2 accumulator cover and pin assembly. (Scheme 130) Remove 1-2 accumulator piston, seal and spring. Remove spacer plate beside 1-2 accumulator. Note check ball and filter locations. (Scheme 120) Remove spacer plates. Remove spring, 3-4 accumulator piston and pin. (Scheme 111): Locating Valve Body Solenoids (Scheme 112): Removing TCC PWM Solenoid (Scheme 113): Removing TCC Bolts (Scheme 114): Removing TCC Solenoid & Wire Harness (Scheme 115): Removing Transmission Fluid Pressure Assembly (Scheme 116): Removing Detent Spring Assembly (Scheme 117): Identifying Valve Body Bolt Location

OIL PUMP, INPUT CLUTCH & REVERSE CLUTCH

1. Ensure TCC solenoid assembly and oil filter are removed before oil pump removal. Remove turbine shaft "O" ring. Remove oil pump retaining bolts. Using Oil Pump Remover (J-37789-A) and Adapter (J-39119), pull oil pump assembly free from case. (Scheme 121)
2. Remove oil pump, seal and gasket. Remove reverse input clutch-to-pump thrust washer from pump. Remove band anchor pin from case. (Scheme 128)Lift out input housing, shaft assembly, reverse input clutch housing and drum assembly. (Scheme 122)

Scheme 121

Removing/Installing Input Clutch Assembly. Scheme 122

2-4 BAND, INPUT GEAR SET & REACTION GEAR SET

1. Remove 2-4 band assembly from case. (Scheme 123) Remove input sun gear. (Scheme 131)
2. Remove input carrier-to-output shaft retainer ring. (Scheme 124) Remove input carrier (planetary). Remove input carrier thrust bearing from reaction carrier shaft. (Scheme 125)
3. Remove input internal gear and reaction carrier shaft assembly. (Scheme 126) Remove reaction sun shell and thrust washer. (Scheme 127) Remove reaction sun gear, thrust washer, low-reverse roller clutch race and roller clutch. (Scheme 131)

Removing/Installing 2-4 Band Assembly. Scheme 123

Removing/Installing Input Carrier To Output Shaft Retainer. Scheme 124

Removing/Installing Input Carrier Assembly. Scheme 125

Removing/Installing Input Internal Gear & Reaction Carrier Shaft Assembly. Scheme 126

Removing Thrust Washer & Reaction Sun Shell. Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

LOW-REVERSE CLUTCH

Note. Parking pawl may require removal to access low-reverse clutch.

1. Remove low-reverse support-to-case retaining snap ring. Remove output shaft support fixture. (Scheme 110) Push up on output shaft to loosen low-reverse clutch support. Remove support retainer spring from low-reverse support. Remove low-reverse support assembly and reaction carrier assembly (planetary). (Scheme 131) Remove output shaft.
2. Remove low-reverse clutch plates. Note locations of components. (Scheme 132) Remove internal reaction gear and thrust bearing. Remove internal reaction gear support-to-case thrust bearing. (Scheme 133)
3. Remove parking lock bracket retaining bolts. Remove lock bracket. Using screw extractor, remove shaft plug. Remove parking pawl shaft, parking pawl and return spring if necessary. (Scheme 135)
4. Using Clutch Spring Compressor (J-23327), compress low reverse clutch spring retainer. Remove spring retaining ring and low-reverse spring assembly. Remove low-reverse clutch piston by applying air pressure in case apply passage. (Scheme 134)

Scheme 132

Removing/Installing Internal Reaction Gear & Thrust Bearing. Scheme 133

Scheme 134

INNER MANUAL SHAFT LINKAGE

Remove manual shaft nut. Remove manual shaft and retainer. Remove parking lock actuator assembly and inner detent lever. Remove manual shaft seal from transmission case. (Scheme 135)

Scheme 135

3RD ACCUMULATOR RETAINER & BALL ASSEMBLY

1. Check 3rd accumulator retainer and ball assembly before removing it. DO NOT remove check valve unless it is leaking. Install servo assembly in bore. Install servo cover and retaining ring. (Scheme 109) Pour clean solvent in bore. Inspect for leaks in transmission case. Replace check valve assembly if it leaks. (Scheme 136) Remove servo assembly.
2. For check valve removal, install No. 4 screw extractor in check valve assembly. Remove check valve. Ensure bore is free of burrs. Installation tool must be made to ensure proper installation depth is obtained. Using a 3/8" O.D. rod, scribe indicator mark at 1.653" (41.98 mm) from end of rod. Install check valve until scribe mark on rod is flush with case. (Scheme 136) Ensure slot in retainer is completely open. Observe 3rd accumulator retainer and ball assembly in 2-4 band servo bore.

Scheme 136

Disassembly

1. Remove reverse input clutch drum-to-oil pump thrust washer, pump-to-case gasket and pump-to-case oil seal ring from pump assembly. (Scheme 137) Remove pump cover retaining bolts. Separate pump cover from pump body. (Scheme 138)
2. Using needle-nose pliers, compress pump slide spring. Remove from pump by pulling straight out. Remove pump vane rings, pump vanes, pump rotor and rotor guide from pump pocket.
3. Remove slide from pump pocket. Remove slide seal and seal support from pump slide. (Scheme 139) Remove pivot pin and pivot pin spring. Remove seal ring and "O" ring from pump slide. Remove seal retainer and seal from pump body.
4. Check condition of pump bushing. If bushing is in good condition, do not remove it. Push inward on converter clutch valve stop to compress spring. Remove snap ring. Remove valve stop, converter clutch apply valve and springs.
5. Using small punch, remove pressure relief spring retaining rivet. Remove relief spring and check ball. Remove oil screen and "O" ring from pump cover. Remove reverse boost valve sleeve. Remove reverse boost valve, pressure regulator valve spring and pressure regulator valve.

Scheme 137

Scheme 138

Scheme 139

1. Inspect all valves, springs, sleeves and bushings for chips, burrs, distortion and free movement in bores. Check pressure relief check ball and spring for damage and distortion. Low line pressure will result if check ball and spring are damaged.
2. Inspect pump cover screen and "O" ring for wear and damage. Clean pump body and cover. Check all bores for obstructions. Inspect mating sides of cover and body for scoring, flatness and damage between channels. Check channels for dirt and damaged passages. Inspect stator shaft and pump body bushings for damage.
3. Inspect rotor and slide for scoring, cracks and damage. Check rotor guide and pump vane rings for excessive wear and damage. Inspect all seals for damage.
4. Measure pump rotor and slide thickness for surface wear. Rotor and slide measurements must fall into same thickness range. See «OIL PUMP COMPONENT THICKNESS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. If rotor and slide measurements do not fall into same thickness range, or are outside of all ranges, oil pump must be replaced as an assembly.

OIL PUMP COMPONENT THICKNESS

Reassembly

1. Install "O" ring and seal ring in groove on back side of pump slide. Retain seal ring using petroleum jelly. Install pivot pin and spring in pump body. Install pump slide. Notch in pump slide must align with pivot pin hole and with flat oil seal ring facing downward in pump pocket. Install slide seal and support. (Scheme 140)
2. Install pump vane ring into pump pocket. Coat rotor guide with petroleum jelly. Install rotor guide on rotor. Install rotor and guide into pump pocket with guide toward pump pocket. Install vanes in rotor. Install vane guide ring. Compress pump slide spring and install into pump pocket. All parts must be even with pump body surface. Install "O" ring on pump screen, and install screen in pump cover with "O" ring end out.
3. Install oil seal in pump body. Install seal retainer. Install pressure relief check ball and spring in pump cover. Install retaining rivet. Install converter clutch valve springs and converter clutch valve. Install valve stop and snap ring. Install pressure regulator valve and spring in pump cover. (Scheme 139)
4. Coat reverse boost valve with petroleum jelly. Install reverse boost valve in boost valve sleeve with small end first. Install reverse boost valve sleeve in pump cover.
5. Install pump cover on pump body. Install retaining bolts finger tight. Align pump body and cover using Alignment Strap (J-21368). (Scheme 141) Place bolt through pump-to-case bolt hole. Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing__torque-specifications). Remove alignment strap. Position pump-to-case gasket on pump, and retain with petroleum jelly.
6. Install oil seal rings on stator hub. Place Stator Shaft Seal Installer (J39855-1) over oil pump stator hub (stator support). (Scheme 142) Set height of installer tool to just above seal groove. Push seal ring over installer tool using Seal Pusher (J38735-3). Install remaining seal rings. Place Stator Shaft Seal Sizer (J39855-2) over stator hub and leave until oil pump installation.
7. Install pump-to-case oil seal on cover. Ensure seal is not twisted. Coat seal with ATF. Install pump-to-drum thrust washer. Ensure tangs on washer engage with holes in hub.

Scheme 140

Scheme 141

Scheme 142

1. Remove the reverse input clutch housing and drum assembly from the input clutch assembly. Remove the stator/selective washer bearing assembly. Remove the selective thrust washer. Remove the 3rd and 4th clutch backing plate retainer ring. Remove all 3rd and 4th clutch plates. Remove the 3-4 clutch boost spring assemblies. (Scheme 131) NOTE: The 3rd and 4th clutch plate stack is different for 2.2L models. The M30 RPO 3-4 Clutch plate stack up is application specific. The stack up on a 2.2L S/T platform is 5 fiber plates, and 6 fiber plates on all other models. The M32 RPO (heavy-duty design) uses 7 fiber plates. These fiber plates are thinner thickness which can not be used in a M30 stack up. M32 fiber plates must not be used in a M30 design.
2. Remove the forward clutch backing plate retainer ring (651). Remove the forward clutch selective backing plate (650). Remove the forward clutch sprag assembly. (Scheme 145)
3. Remove all forward clutch plates (646, 648, 649A, 649B). Remove the input sun gear bearing assembly (637). Remove the input housing to output shaft seal (636). Remove all overrun clutch plates (645A, 645B). (Scheme 144)
4. Install the clutch spring compressor and adapter. Compress the overrun clutch spring using the clutch spring compressor and press. Remove the overrun clutch spring retainer snap ring (635). (Scheme 143)
5. Remove the overrun clutch spring assembly (634). Remove the overrun clutch piston (632). Remove the forward clutch piston (630). Remove the forward clutch housing (628). Remove the 3rd and 4th clutch spring assembly (626). Remove the 3rd and 4th clutch apply ring (625). Remove the 3rd and 4th clutch piston (623). (Scheme 146)

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

1. Place input clutch housing with turbine shaft downward. Install 3-4 piston seals with lips facing away from hub. Install 3-4 piston in input housing.
2. Install 3-4 clutch apply ring. Install "O" ring seal in input clutch housing. Install forward clutch housing. Install seals on forward clutch piston with lips facing away from tangs.
3. Install forward clutch piston in forward clutch housing. Install 3-4 spring on 3-4 clutch apply ring. Install forward clutch assembly on 3-4 spring assembly. Align forward clutch piston legs with tangs of 3-4 apply ring. Install Seal Protector (J-29883) on input housing.
4. Install 3-4 apply ring and forward clutch assembly in input clutch housing. Hold apply ring tangs while installing. DO NOT allow forward clutch piston to separate from assembly. Ensure assembly is firmly seated.
5. Install Seal Protector (J-29883) on input housing. Install overrun clutch piston with hub facing upward. If fully seated, overrun piston should be 3/16" below top of snap ring groove in input housing hub. Install spring assembly on overrun clutch piston. Compress springs, and install snap ring. Install input housing seal.
6. Install 4 overrun clutch plates, starting with steel plate. Align wide notches with case lugs. Install remaining clutch plates, alternating steel and composition plates.
7. Install bearing assembly on input clutch hub. Bearing inner race must face input housing hub. Ensure bearing is centered. Align clutch plate tabs. Install forward clutch sprag assembly in input housing. Align overrun clutch hub with clutch plates.
8. Install forward clutch apply plate in input housing. Install forward clutch waved plate. Ensure all plates are aligned with input housing tangs. Starting with steel plate, install clutch plates, alternating steel and composition plates. Install backing plate and snap ring. (Scheme 147)
9. Using 2 feeler gauges, measure clearance between backing plate and snap ring. (Scheme 148) Ensure clearance is as specified. See «FORWARD CLUTCH CLEARANCE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. If clearance is not as specified, install proper size backing plate with chamfered side upward. See «FORWARD CLUTCH BACKING PLATE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. Install snap ring. FORWARD CLUTCH CLEARANCE SPECIFICATIONS Application Clearance - In. (mm) 9.650" (245 mm) Converter.030-.069 (.76-1.75) 258 mm Converter (1) 298 mm Converter.034-.074 (.86-1.88) 300 mm Converter.034-.074 (.86-1.88) (1) Specification is not available from manufacturer. FORWARD CLUTCH BACKING PLATE SPECIFICATIONS Identification Thickness - In. (mm) A.274-.278 (6.96-7.06) B.250-.255 (6.35-6.48) C.227-.232 (5.77-5.89) D.205-.208 (5.21-5.28) E.180-.185 (4.57-4.70)
10. Install apply plate and 3-4 clutch plates. (Scheme 149) Install 3-4 clutch booster spring assemblies. (Scheme 150) Install backing plate with chamfered side upward. Install retaining snap ring. Using feeler gauge, measure clearance between backing plate and first composition plate. (Scheme 151) Clearance should be.035-.083" (.89-2.11 mm).
11. If clearance is not as specified, select proper backing plate to obtain correct clearance. See «3-4 BACKING PLATE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. Air check all clutches at feed holes in turbine shaft. (Scheme 152)
12. During overrun clutch test, air pressure will blow past forward clutch piston seals and exit out forward clutch feed hole in turbine shaft. Turbine shaft seals require sizing and should be installed before oil pump installation. Position Seal Installer (J-36418-1B) on input shaft. (Scheme 153) Adjustment screw in seal installer must be adjusted to obtain correct height for each seal installation. Install 4 turbine shaft seals.

3-4 BACKING PLATE SPECIFICATIONS

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Remove the overrun clutch hub retaining snap ring (638). Remove the overrun clutch hub (639). Remove the forward sprag clutch inner race and input sun gear assembly (640). (Scheme 154)
2. Remove the sprag assembly retainer rings (643). (Scheme 155)

1. Inspect sprag assembly for weak or damaged springs and retainers and worn rollers. Inspect overrun clutch hub for spline damage, excessive wear and open oil passages. Inspect retainer and race for spline damage, surface wear and damaged ring grooves.
2. Replace sprag assembly if damaged. Inspect forward clutch race for spline damage, excessive wear and open oil passages. Inspect input shaft and housing for spline damage, wear and open oil passages.
3. Inspect 3 sealing check balls located in rear of turbine shaft for tightness. Turbine shaft contains one open lubrication hole. Ensure orifice cup plug is installed. Inspect turbine shaft seal areas for roughness and burrs.
4. Inspect check ball located in input housing for free operation. Inspect pistons for wear, damage and porosity. Inspect spring assemblies for damage and distortion.
5. Inspect steel and composition plates for damage. Inspect snap rings for distortion and damage. Check backing plates for flatness and distortion. Inspect clutch apply rings for distortion and damaged tangs.
6. Inspect forward clutch housing check ball for proper operation (if equipped). Inspect housing for cracks and damage in seal areas. Inspect bearings for excessive wear, flatness, damage and flat rollers.

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

1. Install the forward sprag assembly (642) into the forward clutch outer race (644). (Scheme 156)
2. Install the sprag assembly retainer rings (643) into the forward clutch sprag assembly (644). (Scheme 157)
3. Install the forward sprag clutch inner race and input sun gear assembly (640) into the forward sprag and outer race assembly. (Scheme 158)
4. Install the overrun clutch hub (639) onto the sprag clutch inner race and input sun gear assembly (640). Install the overrun clutch hub retaining snap ring (638). (Scheme 159) NOTE: If the forward clutch sprag assembly operates backwards, you have installed the sprag backwards. Reassemble the sprag correctly. Test the forward clutch sprag assembly for proper operation. Position the forward clutch sprag assembly with the input sun gear facing up. (Scheme 160)
5. Important The sun gear should only rotate in a counterclockwise direction. Hold the forward sprag clutch outer race with one hand and rotate the input sun gear with the other hand. Install the forward clutch sprag and input sun gear assembly into the input clutch housing. Index the overrun clutch hub into the overrun clutch plates. (Scheme 161)

LOW-REVERSE SUPPORT

Disassembly & Inspection

Remove inner race and snap ring. Remove roller clutch assembly. Check inner race for damage and surface finish. (Scheme 162) Inspect roller and springs for damage and distortion. Inspect support for loose cam, cracks and damaged surface finish. Replace damaged parts as necessary.

1. Install roller clutch assembly in low-reverse support. (Scheme 162) Place support in case with hub facing downward. Install inner race. Rotate inner race while pushing downward. Use care not to damage roller and springs during installation.
2. Ensure inner race is fully seated. Bottom tangs will be flush with carrier hub when fully seated. Inner race should rotate clockwise and lock counterclockwise with clutch hub downward. Insert support retainer spring into case between case lug and open notch in support.

Scheme 162

1. Remove 4th apply piston and housing from 2nd apply piston assembly. Remove return spring from apply pin. Install Piston Compressor (J-22269-01) on 2nd apply piston. (Scheme 164)
2. Compress 2nd servo apply piston assembly. Remove retainer ring. Separate 2nd apply piston, spring and retainer. Remove retainer ring, washer and spring from apply pin, and remove pin. Remove all oil seal rings. (Scheme 163)

Scheme 163

Scheme 164

Inspect all pistons for porosity and damage. Check for ring groove damage and servo bore in case for any wear which may cut servo seals. Check all springs and oil seal rings for distortion and damage.

Different servo piston housings and 2nd apply pistons are used for different applications. If servo piston housing or 2nd apply piston is replaced, inside dimension of parts must be checked. Measure inside diameter of piston housing and 2nd apply piston. Dimension must be same as original. To reassemble, reverse disassembly procedure. Coat seals with petroleum jelly before assembly.

VALVE BODY

1. Remove the manual valve (340). (Scheme 165)
2. Remove the forward accumulator cover bolts (364) and the forward accumulator cover (363). Remove the forward accumulator spring (356), forward accumulator piston (354), and the forward accumulator pin (355). Remove the low overrun valve spring (362) and the low overrun valve (361). Remove the coiled spring pin (360) and the bore plug (359). Remove the forward abuse valve spring (358) and the forward abuse valve (357). (Scheme 166)
3. Remove the solenoid retainer (395) and the 1-2 shift solenoid (367A). Remove the 1-2 shift valve (366) and the 1-2 shift valve spring (365). (Scheme 167)
4. Remove the solenoid retainer (395) and the 2-3 shift solenoid (367B). Remove the 2-3 shuttle valve (369) and the 2-3 shift valve (368). (Scheme 168)
5. Remove the coiled spring pin (360). Remove the 1-2 accumulator valve sleeve (372). Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370). (Scheme 169)
6. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). Remove the pressure control solenoid (377). Compress the actuator feed limit valve spring (375). Remove the bore plug retainer (395) and release the spring slowly. Remove the bore plug (376). Remove the actuator feed limit valve spring (375) and the actuator feed limit valve (374). (Scheme 170)
7. Remove the solenoid retainer (395) and the 3-2 control solenoid (394). Remove the 3-2 control valve (391) and the 3-2 control valve spring (392). (Scheme 171)
8. Remove the bore plug retainer (395) and the bore plug (381). Remove the 3-2 downshift valve spring (390) and the 3-2 downshift valve (389). Remove the coiled spring pin (360) and the bore plug (359). Remove the reverse abuse valve spring (388) and the reverse abuse valve (387). (Scheme 172)
9. Remove the bore plug retainer (395) and the bore plug (381). Remove the 3-4 shift valve spring (386) and the 3-4 shift valve (385). (Scheme 173)
10. Remove the bore plug retainer (395) and the bore plug (381). Remove the regulator apply valve (380) and the regulator apply spring (397) and the isolator valve (398). (Scheme 174)
11. Remove the bore plug retainer (395) and the bore plug (381). Remove the 3-4 relay valve (384) and the 4-3 sequence valve (383) and the 4-3 sequence valve spring (382). (Scheme 175)

Inspect valves and sleeves for scoring and cracks. Ensure valves move freely in bores. Inspect valve body for cracks and scored bores. Inspect machined surfaces for damage. Inspect springs for damaged coils. Replace damaged parts as necessary.

Note. Lubricate all parts with Dexron®-lll automatic transmission fluid before installation.

Note. For Reassembly procedures, reverse the disassembly of the valve body in this section. See VALVE BODY

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Cleaning & Inspection

Clean transmission case and dry with compressed air. Inspect case assembly for damage, cracks and damaged bolt hole threads. Inspect valve body surface for flatness and land damage. Check case oil passages for restrictions and blockage. Blow compressed air through all case passages. (Scheme 176) Inspect case internal clutch plate lugs for damage and wear. Inspect servo and accumulator bores for damage. Inspect all snap ring grooves for damage.

Scheme 176

1. Clean all parts and dry with compressed air. Inspect reaction and input carriers for pinion gear damage, excessive wear and improper staking of pinion pins. Inspect carrier bearings for heat damage, flatness and roller condition. Place output shaft sleeve inside reaction carrier and input carrier.
2. Rotate sleeve and note smoothness of bearing operation. Replace carrier assembly if roughness is felt. Check pinion gear end play on reaction and input carriers. (Scheme 177)
3. Pinion gear end play should be.008-.024" (.20-.61 mm). Inspect internal reaction gear and support for cracks and damaged splines. Inspect low-reverse clutch plates for wear and signs of excessive heat.
4. Inspect low-reverse clutch piston for roughness or damage in seal ring area. Inspect retainer ring and spring assembly for damage. Inspect sun and internal gears and supports for spline and bushing wear and damage. Replace damaged parts as necessary.

Scheme 177

Clean all parts and dry with compressed air. Inspect 1-2 and 3-4 accumulator parts for damage to pistons or housing. Inspect for flatness and condition of accumulator, oil passage plate and gasket. Inspect wiring harness leads and connectors for damage. Inspect speed sensor rotor teeth for damage and distortion.

TRANSMISSION REASSEMBLY

Note. To identify bushing, seal, thrust bearing and thrust washer locations and direction, refer to appropriate illustration. (Scheme 188)and (Scheme 189).

1. Place transmission in a vertical position. Install seals on low-reverse clutch piston. Apply petroleum jelly to seals. Align and install piston with notch in bottom of transmission case (695). Ensure piston is fully seated and parking pawl aligns with opening in piston wall. (Scheme 178) Install the low and reverse clutch spring assembly (694). Using the Clutch Spring Compressor (J23327-1), compress the low and reverse clutch spring assembly (694). Using the Snap Ring Remover and Installer (J36850), install the low and reverse clutch retainer ring (693). (Scheme 179)
2. Coat bearing assembly with petroleum jelly. Install bearing assembly on case hub with outside bearing race toward case hub. Install internal reaction gear and support. Install bearing assembly onto support with outside bearing race toward support. Install oil deflector (if equipped) and reaction carrier assembly in case. (Scheme 131)
3. Place waved plate on work bench. Install 5 composition plates and 4 steel plates alternately, starting with composition plate. Install low-reverse support. Apply light pressure to low-reverse support. Do not flatten waved plate. Measure height of clutch pack from work bench to top of low-reverse support. (Scheme 180)
4. Using height dimension, determine proper selective spacer plate to be used. See «SPACER PLATE SELECTION»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. SPACER PLATE SELECTION Measured Clutch Pack Height - In. (mm) (1) Identification Plate Thickness - In. (mm) 1.084-1.105 (27.53-28.07) None.066-.072 (1.67-1.85) 1.105-1.125 (28.07-28.58) "0".046-.052 (1.17-1.31) 1.064-1.084 (27.03-27.53) "1".087-.092 (2.19-2.34) (1) Clutch pack height is measured without spacer plate in position.
5. Place spacer plate between waved plate and first composition plate with identification facing upward. Measure overall height of clutch pack. Overall height should be 1.15-1.18" (29.2-29.9 mm). Install low-reverse clutch pack into transmission case. Ensure clutch plates align with splines of reaction carrier. Ensure steel plates are properly indexed in transmission case. (Scheme 181)
6. Install low-reverse support in case with hub downward. Install inner race by pushing downward while rotating until it is fully engaged. Bottom tangs will be flush with hub when fully installed. Install spring retainer in case between case lug and open notch in support. Install low-reverse snap ring. (Scheme 182)

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

REACTION & INPUT GEAR SETS

1. Install retainer ring on reaction sun gear (if removed). Install sun gear into reaction carrier. Install thrust washer on low-reverse clutch race. Install reaction sun gear shell on reaction sun gear.
2. Install thrust washer on reaction sun gear shell. Ensure thrust washer tangs engage on gear shell. Install input internal gear and reaction carrier shaft in sun gear shell. Carrier shaft splines must engage with reaction carrier. (Scheme 131)
3. Install thrust washer on reaction carrier shaft. Outer race must face toward reaction carrier shaft. Install output shaft in transmission. Ensure output shaft engages with all parts.
4. Install Output Shaft Support (J-29837-A). (Scheme 110) Adjust support so output shaft is positioned upward as far as possible. Install input carrier (planetary) assembly with hub end down on output shaft. Install NEW retainer ring on output shaft. Remove output shaft support. Install input sun gear, indexing gear end with input carrier pinions.

REVERSE INPUT ASSEMBLY & INPUT CLUTCH

1. Install the selective thrust washer (616) on the input housing (621). Install the stator shaft/selective washer bearing assembly (615) on the input housing (621). The black race on the bearing goes toward the oil pump. Install the reverse input clutch assembly (605) on the input housing (621). Index the reverse input clutch plates with the input clutch hub. Make certain all clutch plates are fully engaged. (Scheme 183)
2. Install reverse and input clutch assemblies in transmission case as an assembly. Align 3-4 clutch plates of input assembly with input internal gear. Assembly is fully seated when reverse input clutch housing is just below oil pump face of case. (Scheme 184)

Scheme 183

Scheme 184

OIL PUMP ASSEMBLY

1. Ensure turbine shaft seals on input shaft have been sized using Seal Sizer (J-36418-2A). (Scheme 153) Install aligning pins in 2 opposing pump bolt holes in transmission case. Ensure thrust washer is installed on rear of oil pump. Thrust washer can be retained using petroleum jelly.
2. Remove input shaft Seal Sizer (J-36418-2A). Remove Stator Shaft Seal Sizer (J39855-2). Install oil pump into case, aligning filter and pressure regulator holes with holes in case. Install retaining bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing__torque-specifications). Place transmission in a horizontal position.
3. Turbine shaft should rotate by hand. If turbine shaft will not rotate, loosen pump retaining bolts and attempt to rotate shaft again. If shaft now turns, reverse and input assemblies have not been indexed properly or some other assembly problem has occurred, such as thrust washer not positioned properly.
4. Check transmission end play. See «TRANSMISSION END PLAY CHECK»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing__transmission-end-play-check). Transmission end play should be.005-.036" (.13-.91 mm). Install torque converter. Ensure converter hub is aligned with oil pump. Install torque converter retaining strap to hold converter.

2-4 BAND & SERVO ASSEMBLY

1. Install 2-4 band in case. Align band anchor pin end with case pin hole. Install band anchor pin in case. (Scheme 128) Ensure band anchor pin aligns with end of 2-4 band.
2. Install 2-4 servo assembly into case, and index apply pin on band end. Check for proper engagement of apply pin on band end. Recheck 2-4 servo apply pin selection to ensure correct pin is installed.
3. Remove 4th apply piston and return spring. (Scheme 163) Remove retainer ring, washer, apply pin spring and 2nd apply pin. Install Piston Compressor (J-22269-01) on 2nd apply piston. (Scheme 164)
4. Remove retainer ring, cushion spring and spring retainer. Install Band Apply Pin Tool (J-33037) and apply pin. (Scheme 185) Apply 100 INCH lbs. (11 N.m) torque.
5. White line on band apply tool should be within gauge slot if pin length is correct. If White line is not within gauge slot, inspect 2-4 band and reverse input drum for wear and damage during disassembly.
6. Servo pin length must be checked during reassembly. Servo pin is preset and must not be readjusted. Different length servo pins are available. See «SERVO PIN SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table. Select proper length servo pin. Reassemble 2-4 servo. Install servo cover and "O" ring. Compress cover and install cover retaining ring. Index ends of retaining ring with slot in case.

SERVO PIN SPECIFICATIONS

Scheme 185

TRANSMISSION END PLAY CHECK

1. Install Pump Remover/End Play Fixture (J-24773-A) and End Play Adapter (J-25022-A) on end of turbine shaft. (Scheme 186) Clamp dial indicator on long bolt with indicator tip on end play fixture. Zero dial indicator.
2. Pull up on end play fixture. Measure transmission end play. Transmission end play should be.005-.036" (.13-.91 mm). If transmission end play is not within specification, selective thrust washer must be changed between oil pump and input housing. (Scheme 131) Install appropriate thrust washer, and recheck end play. See «OIL PUMP THRUST WASHER SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing) table.

OIL PUMP THRUST WASHER SPECIFICATIONS

Scheme 186

1. Install 3-4 accumulator piston pin in case. Install 3-4 piston seal on piston. Install 3-4 accumulator piston on pin. Legs of piston must face valve body.
2. Install 3-4 accumulator spring. Install oil screens in proper locations. (Scheme 187) (Scheme 120)for check ball and filter installation locations. Install alignment pins in transmission case to aid spacer plate and valve body installation. Install spacer plate gasket and spacer plate. Install spacer plate support.
3. Install 1-2 accumulator spring, oil seal ring and 1-2 accumulator piston. Install accumulator cover and bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing__torque-specifications).
4. Coat check balls with petroleum jelly. Install check balls in proper locations in valve body. (Scheme 119)and (Scheme 120). Install manual valve link. Ensure manual valve link is properly seated in manual valve. (Scheme 118) Improper positioning may prevent vehicle operation in "D" range. NOTE: Improper positioning of throttle valve link will result in erratic shift points or high oil pressure.
5. Install valve body and retaining bolts. Ensure correct length and location of bolts. (Scheme 117) Install detent spring. Install detent spring bolt. Install transmission fluid pressure manual valve position switch. Install TCC solenoid. Install valve body bolts that secure wiring harness. Tighten all valve body bolts to specification. See «TORQUE SPECIFICATIONS»(/cadillac/escalade/gmt800-2001-2006/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul-testing__torque-specifications).
6. Install TCC PWM solenoid. Install retainer clip. Install electrical connectors to switches and solenoids. (Scheme 111) Install oil filter and "O" ring. Install transmission oil pan.

Scheme 187

1. Install speed sensor rotor retaining clip on output shaft. Install "O" ring in output shaft sleeve. Install output shaft sleeve on output shaft. DO NOT position output shaft sleeve past machined surface of output shaft. Install seal ring on extension housing.
2. Position extension housing on transmission case. Install retaining bolts. Install oil seal in extension housing. Install speed sensor assembly. Install retainer and bolt. Tighten bolt to specification. Install outside electrical connector. Install PNP switch and manual shift lever. See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION.

Scheme 188

Scheme 189

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSMISSION SPECIFICATIONS

TRANSMISSION SPECIFICATIONS

See also:
• MODEL IDENTIFICATION
• TORQUE SPECIFICATIONS
• VALVE BODY
• TRANSMISSION END PLAY CHECK