Reassembly Cadillac Escalade GMT800

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)