Automatic Transmission - 4l80-e/4l85-e (Overhaul) Chevrolet Chevy Express G2500

Fastener Tightening Specifications

Fastener Tightening Specifications

Fluid Capacity Specifications (Overhaul)

Fluid Capacity Specifications (Overhaul)

End Play Specifications

End Play Specifications

Overrun Clutch Housing Selective Thrust Washer Specifications

Overrun Clutch Housing Selective Thrust Washer Specifications

Output Shaft Selective Thrust Washer Specifications

Output Shaft Selective Thrust Washer Specifications

Oil Pump Specifications

Oil Pump Specifications

Transmission General Specifications

Transmission General Specifications

Low and Reverse Band Servo Piston Pin Specification Chart

Refer to the chart in order to determine the correct low and reverse band servo pin length to use. A, B and C on the chart refer to markings on the J 21370-10 Refer to Band Apply Pin Gauge. See Special Tools and Equipment . Numbers 1-7 match the correct piston pin length to the J 21370-10 See Low and Reverse Band Servo Apply Piston Pin Check for land indicated by the low and reverse band servo pin inspection procedure.

Scheme 72

Servo Piston Pin Selection

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Torque Converter Assembly Removal

1. Remove the transmission torque converter assembly.
2. Inspect the torque converter assembly for the following: External damage Metal particles found after flushing the oil cooler and the cooler lines External leaks in the hub weld area The torque converter pilot is damaged or fits poorly into the crankshaft Internal failure of the stator roller clutch Contamination from the engine coolant Excessive end play (Refer to «Torque Converter End Play Inspection»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul__torque-converter-end-play-inspection) ).

Torque Converter End Play Inspection

Tools Required

1. J 26900-13 Magnetic Indicator Base. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 39195 Converter End Play Check Tool. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Place the J 39195 base into the torque converter assembly (1). The J 39195 will bottom itself on the face of the stator.
2. Insert the T-handle forcing screw of the J 39195 into the base and hand tighten.
3. Using the J 26900-13 , position the J 8001 so that the dial indicator tip is in the center of the J 39195 T-handle.
4. Push down on the J 39195 T-handle to bottom the stator.
5. Preload the J 8001 .
6. Set the J 8001-3 to 0.
7. Pull up on the J 39195 T-handle.
8. Inspect the reading on the dial indicator. The total end play should be 0.0-0.38 mm (0.0-0.015 in).
9. Repeat this procedure several times in order to get an accurate measurement.
10. Remove the tools.

Transmission Holding Fixture Installation

Tools Required

1. J 3289-20 Holding Fixture Base Assembly. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 8763-02 Holding Fixture. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38655 Holding Fixture Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the J 8763-02 and the J 38655 onto the transmission assembly.
2. Install the transmission assembly and the J 8763-02 into the J 3289-20 .
3. Lock the J 8763-02 in place with the locking pin.

Draining Transmission Fluid

1. Place a suitable fluid collection pan under the transmission assembly.
2. Slowly rotate the transmission so that the input shaft is up, in order to drain the transmission fluid out of the case extension.
3. Remove the collection pan and properly dispose of the transmission fluid.

Speed Sensor Assembly Removal

1. Remove the input speed sensor bolt (23).
2. Remove the input speed sensor (22A).
3. Remove the output speed sensor bolt (23).
4. Remove the output speed sensor (22B), (output speed sensor plug on 4WD model).
5. Inspect the speed sensors for damage.

Case Extension Assembly Removal

Tools Required

1. J 23129 Universal Seal Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 6125-1B Slide Hammer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Using the J 23129 and the J 6125-1B , remove the prop shaft front slip yoke seal assembly (20) (model dependent).
2. Remove the case extension bolts (21).
3. Remove the (19).
4. Remove the case extension seal (15).
5. Remove the following components and inspect for damage and wear: The output shaft seal (675) (for some models) The transmission output shaft yoke seal sleeve (682) and output shaft seal (683) (for some models) The bearing retainer ring (16), case extension ball bearing assembly (17), and bearing spacer (18) (for some models)

Transmission Oil Pan Removal

1. Remove the transmission oil pan bolts (27).
2. Remove the transmission oil pan (28).
3. Inspect the transmission oil pan (28) for damage or contact with the oil filter.
4. Remove the transmission oil pan gasket (29).
5. Remove the transmission oil pan magnet (30).

Transmission Oil Filter Assembly Removal

1. Remove the transmission oil filter assembly (31).
2. Inspect the filter neck seal assembly (32) for damage.
3. Remove the filter neck seal assembly (32) from the case, if necessary.

Transmission Wire Harness Removal

1. Disconnect the wire harness connectors from the electrical components.
2. Remove the transmission wiring harness assembly (34) from the wiring harness clamps (33).
3. Remove the transmission wiring harness assembly (34) from the case. Use a 1-5/16 inch 12-point socket in order to release the pass-through connector retaining clips from the case.
4. Remove the pass thru connector O-ring seal (36) and replace.

Control Valve Body Assembly Removal

1. Remove the transmission fluid pressure manual valve position switch (TFP manual valve position switch) bolts (76) and the TFP manual valve position switch (40).
2. Remove the control valve body assembly bolts (35).
3. Remove the manual shift shaft detent spring assembly (41).
4. Remove the control valve body assembly bolt (35) and the lube oil pipe retainer (37).
5. Remove the lube oil pipe (39).
6. Remove the control valve assembly (44) including the following: The 3rd and 4th clutch accumulator housing (51) The control valve body gasket (45) (not shown) The control valve body spacer plate (46) (not shown) The accumulator housing gasket (47) (not shown)
7. Remove the manual valve (319) from the control valve assembly to prevent damage.
8. Inspect the manual valve (319) for nicks and burrs.
9. Remove the control valve body spacer plate gasket (48) from the case. The gasket may stick to the spacer plate.
10. Remove the TCC solenoid valve screen assembly (75) from the case passages.
11. Inspect the TCC solenoid valve screen assembly (75) for debris and damage.
12. Remove the 8 control valve body ball check valves (54).

Manual 2-1 Band Servo Assembly Removal

1. Remove the manual 2-1 band servo assembly (55-58).
2. Remove the servo piston cushion spring (60).
3. Inspect the servo piston cushion spring (60) for distortion.
4. Inspect the servo piston case bore for wear and scoring.

Low and Reverse Band Servo Assembly Removal

1. Remove the low and reverse band servo cover bolts (61).
2. Remove the low and reverse band servo cover (62).
3. Remove the low and reverse band servo cover gasket (63).
4. Inspect the low and reverse band servo cover (62) for damage.
5. Remove the low and reverse band servo assembly (64-73).
6. Remove the low and reverse accumulator piston spring (74) from the transmission case.
7. Inspect the low and reverse band servo transmission case bore for wear and scoring.
8. Inspect the low and reverse accumulator piston spring (74) for distortion.

Low and Reverse Band Servo Piston Pin Check

Tools Required

1. J 21370-10 Band Apply Pin Gage. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38737 Band Apply Pin Checking Tool. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the J 21370-10 into the low and reverse band servo pin bore.
2. Position the J 38737 over the low and reverse band servo bore with the hex hub facing the parking pawl linkage.
3. Fasten the J 38737 to the case with two low and reverse band servo cover bolts (61). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
4. Verify that the J 21370-10 moves freely in the J 38737 and in the low and reverse band servo pin bore.
5. In order to determine the correct low and reverse band servo piston pin length, tighten the hex hub of the J 38737 . Tighten: Tighten the hex hub of the J 38737 to 34 N.m (25 lb ft).
6. Observe the lands on the J 21370-10 in order to determine which land is even with the top edge of the J 38737 . Note the letter (A, B or C) stamped on the J 21370-10 .
7. Refer to the Low and Reverse Band Servo Piston Pin Specification chart, in the «Transmission General Specifications»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul__transmission-general-specifications) , in order to determine the correct pin length to use.

Manual Shift Shaft Removal

1. Remove the manual shift shaft pin (709).
2. Remove the manual shift shaft detent lever nut (712).
3. Remove the manual shift shaft (708).
4. Remove the manual shift shaft seal (707).
5. Inspect the manual shift shaft for the following conditions: Damaged flats or threads Burrs Wear
6. Inspect the manual shift shaft pin (709) for tightness.

Parking System Components Removal

1. Remove the manual shift shaft detent lever assembly (711) and the parking pawl actuator assembly (710).
2. Inspect the manual shift shaft detent lever assembly (711) and the parking pawl actuator assembly (710) for cracks, burrs or damage.
3. Remove the parking pawl actuator bracket (713) and bolts (714).
4. Inspect the parking pawl actuator bracket (713) for cracks, burrs or damage.
5. Remove the parking pawl spring (705).
6. Inspect the parking pawl spring (705) for distortion or damage.
7. Remove the parking pawl shaft hole plug (701) from the transmission case using a screw extractor.
8. Remove the parking pawl shaft retainer (704).
9. Remove the parking pawl shaft (702).
10. Remove the parking pawl (703) from the transmission case.
11. Inspect the parking pawl (703) for cracks, burrs or damage.
12. Inspect the parking pawl shaft (702) for damage and proper fit.

Front End Play Check

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 25025-B Guide Pin Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 28585 Snap Ring Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the bolt holes on the transmission case assembly (7).
2. Assemble the J 8001-3 onto the dial indicator holder. Index the J 8001-3 to the end of the turbine shaft (502).
3. Eliminate any slack by pressing down on the turbine shaft (502).
4. Using the J 28585 , apply upward pressure on the output carrier assembly to remove free play in the retainer ring.
5. Set the J 8001-3 to 0.
6. Pull up on the turbine shaft (502) while holding up the output carrier assembly with the J 28585 . The correct end play is between 0.102-0.559 mm (0.004-0.022 in).
7. Record this measurement for future reference.
8. Remove the tools.

Rear Unit End Play Check

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 25025-B Guide Pin Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the case extension bolt holes on the transmission case assembly (7).
2. Push in the output shaft assembly (671) to remove any slack.
3. Assemble the J 8001-3 onto the dial indicator holder. Index the J 8001-3 to the end of the output shaft (671).
4. Set the J 8001-3 to 0.
5. Move the output shaft (671) in and out, noting the amount of end play. The correct end play is between 0.127-0.635 mm (0.005-0.025 in).
6. Record this measurement for future reference.
7. Remove the tools.

Transmission Oil Pump Assembly Removal

Tools Required

1. J 23129 Universal Seal Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 6125-1B Slide Hammer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 45053 Universal Clamp Press. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the turbine shaft front oil seal ring (2).
2. Using the J 23129 and the J 6125-1B , remove the torque converter oil seal assembly (201).
3. Remove the 7 oil pump bolt and seal assemblies (3).
4. Attach the J 45053 to the oil pump shaft. Tighten the bolts.
5. Turn the handle of the J 45053 down onto the turbine shaft in order to raise the oil pump assembly (4) out of the case.
6. Remove the oil pump assembly (4).
7. Remove the J 45053 .
8. Remove the transmission oil pump gasket (6).
9. Remove the selective thrust washer (218).

Scheme 92

Remove the overdrive assembly by grasping the turbine shaft (502) and lifting.

Fourth Clutch Assembly Removal

1. Verify the torque of the fourth clutch housing bolt (26). The torque should be 23 N.m (17 lb ft) minimum.
2. Remove the fourth clutch housing bolt (26).
3. Remove the fourth clutch housing (529) from the transmission case assembly.

Tools Required

J 38358-A Forward Clutch Assembly Remover/Installer. See Special Tools and Equipment .

Removal Procedure

1. Remove the overdrive carrier/forward clutch thrust bearing assembly (601). The bearing may be stuck to the overrun clutch housing assembly.
2. Using the J 38358-A , remove the forward clutch housing assembly (602).
3. Remove the forward clutch housing thrust washer (612).

J 38733 Direct Clutch Assembly Remover/Installer. See Special Tools and Equipment .

Scheme 93

Using the J 38733 , remove the direct clutch housing assembly (623).

Manual 2-1 Band Assembly Removal

1. Remove the manual 2-1 band assembly (628).
2. Inspect the manual 2-1 band assembly for the following conditions: Wear Pitting Flaking Cracks

Intermediate Clutch Assembly Removal

1. Remove the intermediate clutch backing plate retainer ring (629).
2. Remove the intermediate clutch backing plate (630) and the intermediate clutch plates (631, 632) (4 each).
3. Remove the intermediate clutch wave plate (684).
4. Inspect the intermediate clutch plates (631, 632, 684) for the following conditions: Wear Pitting Flaking Cracks
5. Inspect the intermediate clutch backing plate (630) for the following conditions: Burrs Dirt

Center Support and Gear Unit Assembly Removal

Tools Required

1. J 6116-A Rear Gear Holding Fixture. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 21364-A Rear Gear Holding Fixture Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38868 Lower Gear Unit Assembly Remover/Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. J 6129 Handle. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the center support bolt (25).
2. Remove the rear oil cooler pipe fitting (90).
3. Inspect the rear oil cooler pipe fitting (90) for damaged threads.
4. Inspect the rear oil cooler pipe fitting seal (91) for nicks or cuts.
5. Remove the center support retainer ring (633).
6. Attach the J 38868 to the transmission main shaft.
7. Tighten the thumb screw on the J 38868 .
8. Install the J 6129 to the J 38868 .
9. Turn the J 6129 so that the handle shaft contacts the transmission main shaft.
10. Remove the center support and gear unit assembly (640-672) by lifting the J 38868 with the J 6129 .
11. Remove the J 6129 and the J 38868 .
12. Place the center support and gear unit assembly (640-672) into the J 21364-A (not visible in the illustration) and then into the J 6116-A .

Low and Reverse Band Removal

1. Remove the center support spacer (643).
2. Remove the selective thrust washer (674) from the transmission case.
3. Remove the low and reverse band assembly (657).
4. Inspect the low and reverse band assembly (657) and the selective thrust washer (674) for wear and damage.

Output Shaft Seal Removal

Tools Required

1. J 6125-1B Slide Hammer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 23129 Universal Seal Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the output shaft seal retainer ring (14).
2. Inspect the output shaft seal retainer ring (14) for damage.
3. Using the J 23129 and the J 6125-1B , remove the output shaft seal (13).

J 36850 Assembly Lubricant. See Special Tools and Equipment .

Inspection Procedure

1. Inspect the transmission case for the following: Cracks Porosity Connected passages Scored bushing Excess gasket material left on any case surfaces
2. Inspect all threaded holes for damage. Use a Heli-Coil kit in order to repair damage to the threaded holes.
3. Air check all fluid passages. Refer to the hydraulic fluid flow diagrams and the fluid passage in «Fluid Passages»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. Inspect the manual 2-1 band servo bore and the low and reverse band servo bore for the following: Porosity Burrs Damage
5. Inspect the intermediate clutch plate lugs for damage.
6. Inspect the retainer ring grooves for damage.
7. Inspect the case center support bolt hole for damage.
8. Inspect the oil cooler pipe fitting holes for damage.
9. Inspect the vent pipe for damage.
10. Inspect the lube oil orifice cup plug with seal (some models) for damage.
11. Inspect the low/reverse band anchor pins and intermediate band anchor pins for proper position and tightness.
12. Inspect the manual shaft bore for damage and porosity.
13. Clean all of the transmission case components using clean solvent.

J 41505 Output Shaft Seal Installer. See Special Tools and Equipment .

Installation Procedure

1. Using the J 41505 , install a new output shaft seal (13).
2. Install the output shaft seal retainer ring (14).

Parking System Components Installation

1. Install the parking pawl shaft (702) and the parking pawl (703).
2. Install the parking pawl shaft retainer (704).
3. Install the parking pawl spring (705).
4. Apply sealer GM P/N 12345382 or equivalent, to the parking pawl shaft hole plug (701).
5. Using a 5/16 inch diameter rod, install the parking pawl shaft hole plug (701).
6. Assemble the manual shift shaft detent lever assembly (711) to the parking pawl actuator assembly (710).
7. Install the parking pawl actuator assembly (710) over the parking pawl.
8. Install the manual shift shaft seal (707).
9. Partially install the manual shift shaft (708).
10. Install the manual shift shaft detent lever nut (712) onto the manual shift shaft (708).
11. Fully install the manual shift shaft (708).
12. Install the manual shift shaft pin (709) onto the manual shift shaft (708).
13. Tighten the manual shift shaft detent lever nut (712). Tighten: Tighten the nut to 24 N.m (18 lb ft).
14. Install the parking pawl actuator bracket (713).
15. Install the parking pawl actuator bracket bolts (714). Tighten: Tighten the bolts to 24 N.m (18 lb ft).

1. J 28585 Snap Ring Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Refer to the rear unit end play measurement taken during disassembly. If the rear unit end play measurement is not within specifications, use the removed selective thrust washer (674) and the Output Shaft Selective Thrust Washer Specifications table in order to select the correct selective thrust washer. Refer to «End Play Specifications»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul__end-play-specifications) .
2. Install the output shaft selective thrust washer (674).
3. Retain the output shaft selective thrust washer (674) with J 36850 or equivalent.
4. Using J 28585 , install the low and reverse band (657).
5. Install the center support spacer (643) into the case so it rests on the shoulder at the bottom of the case splines. The center support spacer opening should be placed at the 9 o'clock position.

Center Support and Gear Unit Assembly Disassemble

1. Remove the center support assembly (640) from the reaction carrier assembly (651).
2. Remove the reaction carrier thrust washer (642) (brass). The thrust washer may be stuck to the center support assembly.
3. Remove the sun gear shaft assembly (649).
4. Inspect the sun gear shaft assembly (649) for the following: Nicked, scored or worn bushings Damaged splines and teeth Cracks
5. Remove the reaction carrier assembly (651) from the output carrier assembly (661).
6. Remove the low clutch roller assembly (644) from the reaction carrier assembly (651).
7. Inspect the reaction carrier assembly (651) for the following: The pinion gear and pocket thrust surfaces for damage Cracks or damage to band apply surface Pinion gear damage Pinion gear pin for proper location (walking) The bushings for damage
8. Inspect the low clutch roller assembly (644) for damage to the rollers, springs and cage surfaces.
9. Remove the sun gear front thrust bearing assembly (647).
10. Remove the sun gear thrust bearing races (646, 648). One race (646) may be stuck to the center support assembly.
11. Remove the sun gear (650).
12. Remove the output carrier thrust washer (659) from the output carrier assembly (661).
13. Inspect the thrust washer, the bearing assembly and the bearing races for damage.
14. Inspect the sun gear teeth for damage.
15. Turn the output carrier assembly (661) over so that the output shaft assembly (671) faces up.
16. Remove the output shaft thrust washer (673).
17. Remove the output shaft retainer ring (672).
18. Remove the output shaft assembly (671).
19. Inspect the output shaft assembly (671) for the following: Stripped splines Damaged teeth Cracks Damage to the bushing
20. Remove the rear internal gear thrust bearing assembly (647) and the thrust bearing races (648, 669) from the rear internal gear (666). The thrust bearing may be stuck to the output shaft assembly (671).
21. Inspect the thrust bearing assembly and bearing races for damage.
22. Remove the rear internal gear (666) and the main shaft (662) from the output carrier assembly (661).
23. Remove the washer (691), the sun gear rear thrust bearing assembly (664) and bearing races (663, 665).
24. Inspect the bearing assembly, and the bearing races for damage.
25. Remove the main shaft retainer ring (670). Hold the main shaft (662) so it will not fall and become damaged.
26. Remove the main shaft (662) from the rear internal gear (666).
27. Inspect the main shaft (662) for damaged splines.
28. Inspect the main shaft (662) for wear.
29. Inspect the rear internal gear (666) for the following: Stripped splines Damaged teeth Wear
30. Clean all components thoroughly.
31. Inspect the output carrier assembly (661) for the following: Excessive wear Damage to the parking pawl lugs Damage to the pinion gears Excessive wear to the pinion gear steel and brass washers Damage to the pinion gear and pocket thrust surfaces.
32. Inspect the front internal gear for damage and cracks.
33. Inspect the vehicle speed sensor reluctor ring (660) for tightness and damage.

Scheme 94

Using a feeler gage, measure the pinion washer wear.

End Play Specifications: The correct end play is between 0.228-0.610 mm (0.009-0.024 in).

Scheme 95

Using a feeler gage, measure the pinion washer wear.

End Play Specifications: The correct end play is between 0.228-0.610 mm (0.009-0.024 in).

Scheme 96

Insert the low clutch roller assembly (644) into the reaction carrier assembly (651).

Center Support Assembly Disassemble

Tools Required

1. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38734 Intermediate Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the oil cooler pipe fitting seal (690) from the center support assembly (640).
2. Inspect the center support assembly (640) for damage.
3. Using the J 23327 and the J 38734 , compress the intermediate clutch spring assembly (635).
4. Remove the intermediate clutch spring retainer ring (634).
5. Remove the J 23327 and the J 38734 .
6. Remove the intermediate clutch spring assembly (635).
7. Inspect the intermediate clutch spring assembly (635) for collapsed coils and distortion.
8. Remove the intermediate clutch piston (636). Apply compressed air to the center support bolt hole to aid in piston removal.
9. Remove the inner seal (637) and outer seal (638) from the intermediate clutch piston (636).
10. Inspect the intermediate clutch piston (636) for cracks and damage.
11. Remove the direct clutch housing oil seal rings (639) from the center support assembly hub.
12. Inspect the center support intermediate clutch orifice (530). Orifice Specifications: This needs to be open approximately 0.51 mm (0.020 in).
13. Inspect the oil seal ring pockets for damage.

Center Support Assembly Reconditioning Repair

Tools Required

1. J 39919-1 Center Support Thread Reamer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 39919-2 Center Support Gauge Pin. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

Scheme 97

Note. You may recondition the original center support assembly one time only. You must use the new, larger, service bolt with the reconditioned center support assembly in order to avoid component damage. The service bolt is yellow in color, and the production bolt is black in color.

Perform one of the following steps

1. If the center support assembly has been previously reconditioned, or if the J 39919-2 fits into the bolt hole, you MUST replace the center support assembly and bolt.
2. If the center support has never been previously reconditioned: Insert the J 39919-2 into the center support assembly bolt hole. If the J 39919-2 does NOT fit into the center support bolt hole, you can recondition the center support assembly for reuse. Ream the center support assembly bolt hole to the proper dimension using the J 39919-1 .

Center Support Assembly Assemble

Tools Required

1. J 21363 Intermediate Clutch Inner Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38734 Intermediate Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the oil cooler pipe fitting seal (690) into the center support assembly (640).
2. Lubricate the new inner (637) and outer (638) intermediate clutch piston seals, and the seal pockets in the intermediate clutch piston (636) with DEXRON® III transmission fluid.
3. Install the inner (637) and outer (638) intermediate clutch piston seals onto the intermediate clutch piston (636) with the seal lips facing away from the spring pockets.
4. Using the J 21363 , install the intermediate clutch piston (636) onto the center support assembly (640). Use a fine feeler gauge blade to assist with installing the piston outer seal.
5. Remove the J 21363 .
6. Install the intermediate clutch spring assembly (635). Align the springs with the pockets in the intermediate clutch piston.
7. Using the J 38734 and the J 23327 , install the intermediate clutch spring retainer ring (634).
8. Remove the J 38734 and the J 23327 .
9. Install the new direct clutch housing oil seal rings (639) onto the center support assembly (640).
10. Use J 36850 or equivalent in order to keep the oil seal rings in place.

Center Support and Gear Unit Assembly Assemble

Tools Required

1. J 6116-A Rear Gear Holding Fixture. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Insert the main shaft (662) into the rear internal gear (666).
2. Install the main shaft retainer ring (670) onto the main shaft (662).
3. Install the washer (691) onto the main shaft (662).
4. Install the sun gear rear thrust bearing assembly (664) and bearing races (663, 665) onto the main shaft (662).
5. The lips on the sun gear thrust bearing races (663, 665) should face the sun gear rear thrust bearing assembly (664).
6. Retain the washer, sun gear rear thrust bearing assembly and bearing races with J 36850 or equivalent.
7. Lubricate the output carrier pinion gears (655) with DEXRON® III transmission fluid.
8. Install the main shaft (662) and the rear internal gear (666) into the output carrier assembly (661).
9. Place the assembly into the J 6116-A with the main shaft facing down.
10. Assemble the rear internal gear thrust bearing assembly (647) and races (648, 669). The lips of the sun gear thrust bearing races (648, 669) should face the rear internal gear thrust bearing assembly (647).
11. Place the bearing and race assembly onto the hub of the rear internal gear (666). Retain with J 36850 or equivalent.
12. Install the output shaft assembly (671) into the output carrier assembly (661).
13. Install the output shaft retainer ring (672).
14. Install the output shaft thrust washer (673) on the output shaft assembly (671). Align the output shaft thrust washer tabs with the pockets in the output carrier assembly.
15. Retain the thrust washer with J 36850 or equivalent.
16. Turn the gear unit assembly over and place it into the J 6116-A with the output shaft assembly (671) facing down.
17. Install the output carrier thrust washer (659) into the output carrier assembly (661).
18. Lubricate the reaction carrier pinion gears (655) with DEXRON® III transmission fluid.
19. Install the reaction carrier assembly (651) into the output carrier assembly (661).
20. Rotate the reaction carrier assembly (651) to ease installation.
21. Install the sun gear (650) into the reaction carrier assembly 651). Insert the chamfered inner diameter first. Rotate the sun gear to ease installation.
22. Insert the sun gear shaft assembly (649) with the long splined end into the sun gear (650).
23. Install the longer-lipped sun gear front thrust bearing race (648) onto the sun gear with the lip facing upward.
24. Assemble the sun gear front thrust bearing assembly (647) onto the sun gear front thrust bearing race (648).
25. Install the sun gear front thrust bearing race (646) on the rear hub of the center support assembly (640). Retain the sun gear front thrust bearing race (646) with J 36850 or equivalent.
26. Install the reaction carrier thrust washer (642) (brass) into the recess of the center support assembly (640). Retain the reaction carrier thrust washer (642) with J 36850 or equivalent.
27. Install a new center support assembly (640), or the reconditioned center support assembly, into the reaction carrier assembly (651).
28. Verify correct installation by holding the reaction carrier assembly (651) stationary and rotating the center support assembly (640). The center support assembly (640) should only turn counterclockwise.

Center Support and Gear Unit Assembly Installation

Tools Required

1. J 38868 Lower Gear Unit Assembly Remover/Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 6129 Handle. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 28585 Snap Ring Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Attach the J 38868 and the J 6129 onto the main shaft.
2. Align the bolt hole in the center support with the bolt hole in the case and carefully lower the center support and gear unit assembly (640-672) into the case.
3. Remove the tools.
4. Using the J 28585 , install the center support retaining ring (633). The end gap of the center support retaining ring (633) should be located at the 9 o'clock position with the beveled edge of the retaining ring facing up.

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 25025-B Dial indicator Post Guide Pin Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the case extension bolt holes on the transmission case (7).
2. Push the output shaft assembly (671) in to remove any slack.
3. Install the J 8001-3 on the dial indicator holder. Index the J 8001-3 to the end of the output shaft (671).
4. Set the J 8001-3 to 0.
5. Move the output shaft (671) in and out, noting the amount of end play. End Play Specification: The correct end play is 0.127-0.635 mm (0.005-0.025 in). If the end play is not correct, change the output shaft selective thrust washer (674). Refer to the «Output Shaft Selective Thrust Washer Specifications»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul__output-shaft-selective-thrust-washer-specifications) .
6. Remove the tools.

J 23093 Center Support Alignment Tool. See Special Tools and Equipment .

1. Using the J 23093 , locate the center support 2nd clutch fluid passage through the hole in the case bottom. Refer to «Fluid Passages»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) , Case Fluid Passages illustration.
2. Push the J 23093 toward the low and reverse band servo bore, seating the center support splines against the case splines.
3. Install the new center support bolt (25). Tighten: Maintain pressure on J 23093 while tightening the new center support bolt to 43 N.m (32 lb ft).
4. Ensure that the center support bolt head is seated to the bottom of the case.
5. Install a new rear oil cooler pipe fitting seal (91) onto the rear oil cooler pipe fitting (90).
6. Install the rear oil cooler pipe fitting (90) into the transmission case. Tighten: Tighten the fitting to 35 N.m (26 lb ft).

Intermediate Clutch Assembly Installation

1. Dip all of the intermediate clutch plates in DEXRON® III transmission fluid.
2. Install the intermediate clutch wave plate (684) with the tangs facing down.
3. Install the intermediate clutch plates (631, 632).
4. Install the intermediate clutch backing plate (630).
5. Install the intermediate clutch backing plate retainer ring (629). The opening of the retainer ring (629) should be at the 9 o'clock position.

Scheme 98

Using a feeler gauge, measure the piston travel between the intermediate clutch backing plate and the intermediate clutch backing plate retaining ring (629).

Piston Travel Specification: Piston travel should be 1.02-2.72 mm (0.040-0.107 in).

Scheme 99

Install the manual 2-1 band assembly (628) into the transmission case. Inspect for proper alignment with the anchor pin and inspect for freedom of movement.

Direct Clutch Assembly Disassemble

Tools Required

1. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the intermediate clutch roller retainer retaining ring (627).
2. Remove the intermediate clutch roller retainer (626).
3. Remove the intermediate clutch sprag assembly (624) and race (625) as an assembly.
4. Remove the intermediate clutch roller outer race (625).
5. Inspect the intermediate clutch sprag assembly (624) for damaged rollers, a damaged cage or distorted springs.
6. Remove the direct clutch backing plate retaining ring (616).
7. Remove the direct clutch backing plate (617).
8. Remove the direct clutch plates (611, 618).
9. Remove the direct clutch (waved) plate (609).
10. Inspect the direct clutch backing plate (617) for damage and cracks.
11. Inspect the direct clutch plates (609, 611, 618) for wear, burned, flaking, scoring, and pitting.
12. Install the J 23327 and the J 25018-A onto the direct clutch housing assembly (623).
13. Compress the direct clutch spring assembly (607).
14. Remove the direct clutch spring retainer ring (608).
15. Remove the tools.
16. Remove the direct clutch spring assembly (607).
17. Inspect the direct clutch spring assembly (607) for collapsed coils and distortion.
18. Remove the direct clutch piston assembly (619). The direct clutch piston assembly is reusable unless it is damaged.
19. Inspect the direct clutch piston assembly (619) for damage and cracks.
20. Remove the direct clutch piston intermediate seal (622) from the direct clutch housing assembly (623).
21. Inspect the direct clutch housing assembly (623) for the following: Cracks Wear Restricted/clogged oil passages Free movement of checkballs (rattles)

Direct Clutch Assembly Assemble

Tools Required

1. J 21362-1 Direct Clutch Piston and Inner Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38732-1 Direct Clutch Piston and Outer Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
5. J 38695 Direct Clutch Spiral Retaining Ring Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the direct clutch piston intermediate seal (622) onto the direct clutch housing assembly (623) with the seal lip facing upward.
2. Lubricate the direct clutch piston assembly (619) with DEXRON® III transmission fluid.
3. Install the J 21362-1 and the J 38732-1 onto the direct clutch housing assembly (623). Lubricate the tools with DEXRON® III transmission fluid.
4. Install the direct clutch piston assembly (619) into the direct clutch housing assembly (623) using a rotating motion until the direct clutch piston assembly (619) is seated.
5. Install the direct clutch spring assembly (607).
6. Install the J 23327 and the J 25018-A onto the direct clutch housing assembly (623).
7. Compress the direct clutch spring assembly (607).
8. Install the direct clutch spring retainer ring (608).
9. Remove the tools.
10. Dip all of the direct clutch plates in DEXRON® III transmission fluid.
11. Install the direct clutch (waved) plate (609).
12. Install the direct clutch plates (611, 618).
13. Install the direct clutch backing plate (617).
14. Install the direct clutch backing plate retaining ring (616).
15. Turn the direct clutch housing assembly (623) over.
16. Assemble the intermediate clutch sprag assembly (624) into the intermediate clutch roller outer race (625).
17. Install the intermediate clutch roller outer race (625) with the grooved side facing up: Use a clockwise rotating motion to ease assembly The clutch roller outer race (625) should not rotate counterclockwise
18. Install the intermediate clutch roller retainer (626).
19. Install the intermediate clutch roller retainer retaining ring (627) onto the hub of the direct clutch housing assembly (623).
20. Use the J 38695 in order to complete the installation of the intermediate clutch roller retainer retaining ring (627). Rotate the J 38695 counterclockwise while pressing down.

Direct Clutch Assembly Installation

Tools Required

1. J 24396 Intermediate Clutch Pack Alignment Tool. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38733 Direct Clutch Assembly Remover/Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Using the J 24396 , align the intermediate clutch plates.
2. Apply compressed air through the center support bolt hole to apply the intermediate clutch. Continue applying compressed air to hold the intermediate clutch plates in place until the direct clutch assembly is installed.
3. Remove the J 24396 .
4. Using the J 38733 , install the direct clutch housing assembly (623) into the transmission case. Rotate the direct clutch housing assembly slightly in each direction to ease installation.
5. Remove the J 38733 .

Direct Clutch Piston Travel Check

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 7057 Dial Indicator Plunger Extension. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Attach the J 7057 (not visible in the illustration) to the J 8001-3 .
2. Using the J 8001-1 , mount the J 8001-3 to the transmission case through the opening in the case barrel. Place the J 7057 onto the direct clutch piston assembly.
3. Index the J 8001-3 . Set the dial to 0.
4. Apply 80 psi of air pressure to the direct clutch fluid passage (3rd/Reverse), in the case bottom, in order to actuate the direct clutch piston. Refer to «Fluid Passages»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) , Case Fluid Passages illustration.
5. Measure the direct clutch piston travel. Piston Travel Specification: The piston travel should be 1.27-4.369 mm (0.050-0.172 in).
6. Remove the tools.

Forward Clutch Assembly Disassemble

Tools Required

1. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the direct clutch hub retainer ring (616).
2. Remove the direct clutch hub (615).
3. Remove the direct clutch housing thrust washer (614) (plastic).
4. Remove the forward clutch hub (613).
5. Remove the forward clutch housing thrust washer (612) (bronze). The washer may stick to the forward clutch housing assembly (602).
6. Inspect the direct clutch hub (615) for the following: Spline wear Open lubrication holes A damaged clutch surface
7. Remove the forward clutch steel and composite plates (610, 611).
8. Remove the forward clutch (waved) plate (609).
9. Inspect the forward clutch plates (609-611) for the following: Burning Scoring Flaking Pitting Wear
10. Using the J 23327 and the J 25018-A , compress the forward clutch spring assembly (607).
11. Remove the forward clutch spring retainer ring (608).
12. Remove the tools.
13. Remove the forward clutch spring assembly (607).
14. Inspect the forward clutch spring assembly (607) for collapsed spring coils and distortion.
15. Remove the forward clutch piston assembly (606). The forward clutch piston assembly is reusable if it is not damaged.
16. Inspect the forward clutch piston assembly (606) for cracks.
17. Inspect the seal on the forward clutch piston assembly (606) for cuts, tears, and nicks.
18. Inspect the forward clutch piston intermediate seal assembly (685) for cuts, tears, and nicks.
19. Inspect the forward clutch housing assembly (602) for the following: Wear Restricted/Clogged oil passages Damaged thrust faces Free movement of checkball (rattles)

Forward Clutch Assembly Assemble

Tools Required

1. J 21362-1 Forward Clutch Piston and Inner Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38732-1 Forward Clutch Piston and Outer Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
5. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Lubricate the seal on the forward clutch piston assembly (606) with DEXRON® III transmission fluid.
2. Lubricate the forward clutch piston intermediate seal assembly (685) with DEXRON® III transmission fluid.
3. Install the J 21362-1 over the hub of the forward clutch housing assembly (602).
4. Place the forward clutch piston assembly (606) inside the J 38732-1 and insert the assembly into the forward clutch housing assembly (602).
5. Push down on and slightly rotate the forward clutch piston assembly (606) until it is seated.
6. Remove the tools.
7. Install the forward clutch spring assembly (607).
8. Using the J 23327 and the J 25018-A , compress the forward clutch spring assembly (607).
9. Install the forward clutch spring retainer ring (608).
10. Remove the tools.
11. Dip the forward clutch plates in DEXRON® III transmission fluid.
12. Install the forward clutch (waved) plate (609) into the forward clutch housing assembly (602).
13. Install the steel and composite forward clutch plates (610, 611).
14. Install the direct clutch hub (615).
15. Install the direct clutch hub retainer ring (616).

Forward Clutch Piston Travel Check

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 26900-13 Magnetic Indicator Base. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the overdrive carrier retainer ring (522).
2. Remove the turbine shaft (502).
3. Place the turbine shaft (502) in a soft-jawed vice.
4. Install the forward clutch housing assembly (602) onto the turbine shaft (502).
5. Attach the J 8001-3 to the J 26900-13 .
6. Place an index finger over one side of the forward clutch fluid passage in the turbine shaft (502).
7. Apply air to the other side of the forward clutch fluid passage in the turbine shaft (502). Piston Travel Specification: The piston travel should be 1.27-4.369 mm (0.050-0.172 in).
8. Remove the tools.
9. Remove the forward clutch housing assembly (602) from the turbine shaft (502).

J 36850 Assembly Lubricant. See Special Tools and Equipment .

Assembly Procedure

1. Remove the direct clutch hub retainer ring (616).
2. Remove the direct clutch hub (615).
3. Install the forward clutch housing thrust washer (612) (bronze) on the inside of the forward clutch hub (613). Retain the thrust washer with J 36850 or equivalent.
4. Install the direct clutch housing thrust washer (614) (plastic) on the outside of the forward clutch hub (613). Retain the thrust washer with J 36850 or equivalent.
5. Install the forward clutch hub (613) into the forward clutch housing assembly (602). Rotate the hub slightly in each direction in order to ease installation.
6. Install the direct clutch hub (615) into the forward clutch housing assembly (602).
7. Install the direct clutch hub retainer ring (616).

Forward Clutch Assembly Installation

Tools Required

1. J 38358-A Forward Clutch Assembly Remover/Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Align the direct clutch plates in order to aid in the installation of the forward clutch housing assembly (602).
2. Using the J 38358-A , install the forward clutch housing assembly (602).
3. Install the overdrive carrier/forward clutch thrust bearing assembly (601) (silver side up) onto the forward clutch housing assembly (602). Retain with J 36850 or equivalent.

Fourth Clutch Assembly Disassemble

Tools Required

1. J 38882 Fourth Clutch Spring and Retainer Assembly Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38731-3 Fourth Clutch Piston and Housing Seal Spacer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the fourth clutch backing plate retainer ring (523).
2. Remove the fourth clutch backing plate (524).
3. Remove the fourth clutch plates (525, 526).
4. Place the fourth clutch housing (529) onto the J 38731-3 .
5. Using the J 38882 and the J 23327 , compress the fourth clutch spring assembly (532).
6. Remove the fourth clutch spring retainer ring (533).
7. Remove the J 38882 and the J 23327 .
8. Remove the fourth clutch spring assembly (532).
9. Remove the fourth clutch piston (528).
10. Remove the fourth clutch piston inner seal (527).
11. Remove the fourth clutch piston outer seal (531) from the fourth clutch housing (529).
12. Inspect the fourth clutch orifice (530). Orifice Specification: The small hole in the orifice should be open approximately 0.51 mm (0.020 in).

Fourth Clutch Assembly Assemble

Tools Required

1. J 38731-1 Fourth Clutch Piston and Housing Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38731-2 Fourth Clutch Piston and Housing Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38731-3 Fourth Clutch Piston and Housing Seal Spacer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. J 38882 Fourth Clutch Spring and Retainer Assembly Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
5. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the fourth clutch piston inner seal (527) onto the fourth clutch piston (528).
2. Install the fourth clutch piston outer seal (531) into the fourth clutch housing (529). The seal lip should face the bottom of the piston when the piston is installed.
3. Place the J 38731-1 into the fourth clutch housing (529) through the smaller opening.
4. Place the J 38731-2 onto the larger opening of the fourth clutch piston (528).
5. Place the J 38731-2 and the fourth clutch piston (528) onto the J 38731-3 .
6. Install the fourth clutch piston (528) into the fourth clutch housing (529) by gently pushing down on the fourth clutch housing (529), until the fourth clutch piston (528) is through the fourth clutch housing (529), exposing the retainer ring groove.
7. Remove all tools.
8. Place the fourth clutch spring assembly (532) and the fourth clutch spring retainer ring (533) onto the fourth clutch piston (528).
9. Using the J 38882 , the J 23327 and the J 38731-3 , compress the fourth clutch spring (532).
10. Install the fourth clutch spring retainer ring (533).
11. Remove the tools.
12. Install the fourth clutch plates (525, 526) into the fourth clutch housing (529).
13. Install the fourth clutch backing plate (524). Align the notched tab in the same direction as the steel plate index notches.
14. Install the fourth clutch backing plate retainer ring (523).

Scheme 100

Using a feeler gage, measure the piston travel between the fourth clutch backing plate (524) and the fourth clutch backing plate retainer ring (523).

Piston Travel Specification: Piston travel should be 1.016-2.540 mm (0.040-0.100 in).

Fourth Clutch Assembly Installation

1. Remove the fourth clutch backing plate retainer ring (523) from the fourth clutch housing (529).
2. Remove the fourth clutch backing plate (524).
3. Remove the clutch plates (525, 526).
4. Install the fourth clutch housing (529) into the transmission case assembly.
5. Install a new fourth clutch housing bolt (26).
6. Tighten the fourth clutch housing bolt (26). Tighten: Tighten the bolt to 23-26 N.m (17-19 lb ft).

Overrun Clutch Assembly Disassemble

Tools Required

1. J 38734 Intermediate Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Separate the overdrive carrier assembly (514) from the overrun clutch housing assembly (504).
2. Remove the overdrive clutch roller assembly (512) from the overrun clutch housing assembly (504).
3. Remove the overrun clutch backing plate retainer ring (511) from the overrun clutch housing assembly (504).
4. Remove the overrun clutch backing plate (510) and the overrun clutch plates (508, 509).
5. Inspect the overrun clutch plates (508-510) for burning, scoring, flaking, pitting, and wear.
6. Using the J 23327 and the J 38734 , remove the overrun clutch spring assembly (506).
7. Remove the overrun clutch spring retainer ring (507).
8. Remove the tools.
9. Remove the overrun clutch spring assembly (506).
10. Remove the overrun clutch piston assembly (505).
11. Inspect the overrun clutch spring assembly (506) for collapsed coils and distortion.
12. Inspect the overrun clutch piston assembly (505) for cracks and a cut seal.
13. Inspect the overrun clutch housing assembly (504) for wear, clogged lubrication holes, and damaged thrust surfaces.

Overrun Clutch Assembly Assemble

Tools Required

1. J 38729 Overrun Clutch Piston Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38734 Intermediate Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 23327 Clutch Spring Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the J 38729 onto the overrun clutch housing assembly (504).
2. Lubricate the seal on the overrun clutch piston assembly (505) with DEXRON® III transmission fluid.
3. Assemble the overrun clutch piston assembly (505) into the overrun clutch housing assembly (504).
4. Rotate the overrun clutch piston (505) in order to aid in assembly.
5. Install the overrun clutch spring assembly (506) onto the overrun clutch piston assembly (505).
6. Using the J 23327 and the J 38734 , compress the overrun clutch spring assembly (506).
7. Install the overrun clutch spring retainer ring (507).
8. Install the overrun clutch plates (508, 509).
9. Install the overrun clutch backing plate (510).
10. Install the overrun clutch backing plate retainer ring (511) on the overrun clutch housing assembly (504).

Scheme 101

Using a feeler gage, measure the piston travel between the overrun clutch backing plate (510) and the overrun clutch backing plate retainer ring (511).

Piston Travel Specification: Piston travel should be 0.838-2.38 mm (0.033-0.094 in).

Scheme 102

Using a feeler gage, measure the pinion washer wear.

End Play Specification: The correct end play is between 0.2032-0.6350mm (0.008-0.025 in).

Overdrive Carrier Assembly Disassemble

1. Remove the overdrive carrier pinion gear pin retaining ring (521) from the overdrive carrier assembly (514).
2. Remove the overdrive carrier pinion gear pin retainer (520).
3. Remove one overdrive carrier pinion gear (518) and pin (519) at a time.
4. Inspect the overdrive carrier pinion gear (518), pin (519), roller bearings (517), steel thrust washers (516) and thrust washers (515) for wear or damage.
5. Remove the overrun clutch housing thrust bearing assembly (513) from the overdrive carrier assembly (514). The bearing will fall out when the pinion gears are removed.
6. Inspect the pinion pocket thrust surfaces for burrs.
7. Inspect the overdrive carrier assembly (514) for cracks, damage and wear.
8. Inspect the overrun clutch housing thrust bearing assembly (513).

J 36850 Assembly Lubricant. See Special Tools and Equipment .

1. Install the overrun clutch housing thrust bearing assembly (513) into the overdrive carrier assembly (514). Retain with J 36850 or equivalent.
2. Install one overdrive carrier pinion gear (518) and its roller bearings (517) and thrust washers (515, 516), into the overdrive carrier assembly (514) at the location marked at disassembly.
3. Install the overdrive carrier pinion gear pin (519).
4. Repeat steps 2 and 3 until all 4 pinion gear assemblies are installed in their original locations.
5. Install the overdrive carrier pinion gear pin retainer (520) on the overdrive carrier assembly (514). Align the pinion gear pins with the retainer slots.
6. Install the overdrive carrier pinion gear pin retainer retaining ring (521) on the overdrive carrier assembly (514).

Turbine Shaft Disassemble

1. Remove the turbine shaft rear (501) and intermediate (503) oil seal rings.
2. Inspect the turbine shaft (502) for damage or cracks.
3. Inspect the turbine shaft plug (534) on the end of the turbine shaft (502).

Turbine Shaft Assemble

Tools Required

1. J 38736-1 Turbine Shaft Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38736-2 Turbine Shaft Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38736-3 Turbine Shaft Seal Sizer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
4. J 38736-4 Turbine Shaft Seal Sizer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
5. J 38736-5 Turbine Shaft Seal Pusher. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
6. J 38736-6 Turbine Shaft Seal Pusher. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Place the J 38736-1 onto the turbine shaft (502).
2. Set the J 38736-1 to position #1.
3. Using the J 38736-5 , install the lower turbine shaft intermediate oil seal ring (501).
4. Remove the tools.
5. With the small chamfered end down, place the J 38736-3 over the lower turbine shaft intermediate oil seal ring.
6. Leave the J 38736-3 on the turbine shaft intermediate oil seal ring for at least 1 minute in order to allow the seal ring to become the proper size.
7. Place the J 38736-1 onto the turbine shaft (502).
8. Set the J 38736-1 to position #2.
9. Using the J 38736-5 , install the upper turbine shaft intermediate oil seal ring (501).
10. Remove the tools.
11. With the large chamfered end down, place the J 38736-3 over the turbine shaft intermediate oil seal ring.
12. Leave the J 38736-3 on the turbine shaft intermediate oil seal ring for at least 1 minute to allow the seal ring to become the proper size.
13. Turn the turbine shaft (502) over.
14. Place the J 38736-2 onto the turbine shaft.
15. Set the J 38736-2 to position #1.
16. Using the J 38736-6 , install the lower turbine shaft rear oil seal ring (503).
17. Remove the tools.
18. With the small chamfered end down, place the J 38736-4 over the lower turbine shaft rear oil seal ring.
19. Leave the J 38736-4 on the turbine shaft rear oil seal ring for at least 1 minute in order to allow the seal ring to become the proper size.
20. Place the J 38736-2 onto the turbine shaft (502).
21. Set the J 38736-2 to position #2.
22. Using the J 38736-6 , install the upper turbine shaft rear oil seal ring (503).
23. Remove the tools.
24. With the large chamfered end down, place the J 38736-4 over the turbine shaft rear oil seal ring.
25. Leave the J 38736-4 on the turbine shaft rear oil seal ring for at least 1 minute in order to allow the seal ring to become the proper size.

Overdrive Carrier Assemble

1. Install the overdrive clutch roller assembly (512) on the overrun clutch housing assembly (504).
2. Install the overdrive carrier assembly (514) on the overrun clutch housing assembly (504).
3. Install the turbine shaft (502) through the overrun clutch housing assembly (504) and the overdrive carrier assembly (514).
4. Install the overdrive carrier retainer ring (522).

J 36850 Assembly Lubricant. See Special Tools and Equipment .

1. Install the turbine shaft and overdrive assembly into the transmission case.
2. Install the overrun clutch housing thrust washer (218) onto the overrun clutch housing assembly (504). Retain with J 36850 or equivalent.
3. Place a straight edge from the oil pump mating surface to the overrun clutch housing thrust washer (218). The 2 surfaces should be flush.

Fourth Clutch Plate Installation

1. Install the fourth clutch plates (525, 526) into the fourth clutch housing (529).
2. Install the fourth clutch backing plate (524). Align the notched tab of the fourth clutch backing plate (524) over the anchor pin in the case.
3. Install the fourth clutch backing plate retainer ring (523).

Transmission Oil Pump Disassemble

1. Remove the transmission oil pump cover bolts (220).
2. Remove the vent passage splash shield (239).
3. Separate the oil pump body assembly (203) and the oil pump cover (206).

Transmission Oil Pump Cover Disassemble

1. Remove the reverse boost valve bushing retainer ring (226) from the oil pump cover (206).
2. Remove the reverse boost valve bushing (227).
3. Remove the reverse boost valve (228).
4. Remove the pressure regulator valve spring retainer (229).
5. Remove the pressure regulator valve inner (238) and outer springs (230).
6. Remove the pressure regulator valve (231).
7. Remove the pressure regulator valve bore plug (232).
8. Remove the pressure regulator valve bore plug pin (211).
9. Inspect the pressure regulator valve components for chips, burrs, distortion, plugged oil passages.
10. Remove the converter regulator valve bore plug pin (211) from the oil pump cover (206).
11. Remove the converter regulator valve bore plug (212).
12. Remove the converter regulator valve spring (213).
13. Remove the converter regulator valve (214).
14. Inspect the converter regulator valve components for chips, burrs, and distortion.
15. Remove the TCC enable valve spring retainer sleeve (215) from the oil pump cover (206).
16. Remove the TCC enable valve spring (216).
17. Remove the TCC enable valve (217).
18. Inspect the TCC enable valve components for chips, burrs, and distortion.
19. Remove the TCC shift valve bore plug retainer ring (221) from the oil pump cover (206).
20. Remove the pressure regulator (TCC shift) valve bore plug (232).
21. Remove the TCC shift valve (223).
22. Remove the TCC shift valve spring (224).
23. Remove the TCC shift valve spring seat (225).
24. Remove the TCC shift valve spring seat pin (211).
25. Inspect the TCC shift valve components for chips, burrs, and distortion.
26. Inspect the oil pump cover vent hole for blockage.
27. Inspect the stator shaft splines for damage.
28. Inspect the turbine shaft bushings (233, 234) for wear, and galling.
29. Remove the overrun clutch housing oil seal rings (219) from the oil pump cover (206).
30. Inspect the overrun clutch housing oil seal ring grooves for nicks, burrs, and debris.

Transmission Oil Pump Cover Assemble

1. Install the TCC shift valve spring seat pin (211) into the oil pump cover (206).
2. Install the TCC shift valve spring seat (225).
3. Install the TCC shift valve spring (224).
4. Install the TCC shift valve (223).
5. Install the pressure regulator (TCC shift) valve bore plug (232).
6. Install the TCC shift valve bore plug retainer ring (221).
7. Inspect the TCC shift valve (223) for free movement in the bore.
8. Install the TCC enable valve (217) into the oil pump cover (206).
9. Install the TCC enable valve spring (216).
10. Compress the TCC enable valve spring (216), and insert a small rod into the fluid passage in order to retain the TCC enable valve spring.
11. Install the TCC enable valve spring retainer sleeve (215).
12. Remove the small rod.
13. Inspect the TCC enable valve (217) for free movement in the bore.
14. Install the converter regulator valve (214) into the oil pump cover (206).
15. Install the converter regulator valve spring (213).
16. Install the converter regulator valve bore plug (212).
17. Install the converter regulator valve bore plug pin (211).
18. Inspect the converter regulator valve (214) for free movement in the bore.
19. Install the pressure regulator valve bore plug pin (211) into the oil pump cover (206).
20. Install the pressure regulator valve bore plug (232).
21. Install the pressure regulator valve (231).
22. Install the pressure regulator valve inner (238) and outer (230) springs.
23. Install the pressure regulator valve spring retainer (229).
24. Assemble the reverse boost valve (228) into the reverse boost valve bushing (227) with the reverse boost valve stem facing out of the bushing.
25. Install the reverse boost valve assembly (227, 228).
26. Install the reverse boost valve bushing retainer ring (226).

Transmission Oil Pump Body to Gear Face Clearance Check

1. Place a straight edge across the face of the oil pump body assembly (203) and the faces of the oil pump gears (204, 205).
2. Measure the clearance between the straight edge and the faces of the oil pump gears. The proper clearance is between 0.017-0.071 mm (0.0008-0.0028 in).

Transmission Oil Pump Body Disassemble

1. Remove the transmission oil pump drive gear (205) and driven gear (204) from the oil pump body (203).
2. Inspect the oil pump body assembly (203) gear pockets, crescent, pump body face and bushing for scoring nicks and wear.
3. Inspect the oil pump drive gear (205) and driven gear (204) for wear.
4. Remove the transmission oil pump seal (5) from the oil pump body assembly (203).
5. Inspect the oil pump body assembly (203) fluid passages for debris.
6. Inspect the oil pump body assembly fluid passages for scored or irregular mating surfaces.
7. Inspect the oil pump body assembly fluid passages for cross channel leaks.
8. Inspect the oil pump body assembly bolt threads for damage.

Scheme 103

Using a straight edge and a feeler gage, inspect the face of the oil pump body assembly (203) for flatness.

J 38693 Oil Pump Seal Installer. See Special Tools and Equipment .

1. Using the J 38693 , install the torque converter oil seal assembly (201).
2. Lubricate the oil pump drive gear (205) and driven gear (204) with DEXRON® III automatic transmission fluid.
3. Install the oil pump driven gear (204) and drive gear (205) with the identification dots facing up.

Transmission Oil Pump Assemble

Tools Required

1. J 21368 Pump Body and Cover Alignment Band. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Assemble the oil pump cover (206) and the oil pump body assembly (203).
2. Install the vent passage splash shield (239).
3. Install the oil pump cover bolts (220). Tighten the bolts with your fingers only.
4. Install an oil pump bolt and seal assembly (3) into an oil pump bolt hole.
5. Install the J 21368 onto the transmission oil pump assembly and tighten.
6. Tighten the 5 oil pump cover bolts (220). Tighten: Tighten the bolts to 24 N.m (18 lb ft) in an alternating pattern.
7. Remove the J 21368 and the oil pump bolt and seal assembly (3).
8. Install the transmission oil pump seal (5) on the oil pump assembly (4).
9. Install the new overrun clutch housing oil seal rings (219) onto the oil pump cover.
10. Ensure that the overrun clutch housing oil seal rings (219) move freely in the grooves.
11. Use J 36850 or equivalent in order to keep the overrun clutch housing oil seal rings in place.

J 25025-1 Guide Pins. See Special Tools and Equipment .

1. Install the J 25025-1 at the 12 o'clock and the 5 o'clock positions.
2. Install the transmission oil pump gasket (6).
3. Install the oil pump assembly (4) into the transmission case assembly.
4. Remove J 25025-1 .
5. Install the 7 transmission oil pump bolt and seal assemblies (3). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
6. Install the turbine shaft front oil seal ring (2).

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 25025-B Guide Pin Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 28585 Snap Ring Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the bolt holes on the transmission case assembly (7).
2. Assemble the J 8001-3 onto the dial indicator holder. Index the J 8001-3 to the end of the turbine shaft (502).
3. Eliminate any slack by pressing down on the turbine shaft (502).
4. Using J 28585 , apply upward pressure on the output carrier assembly to remove free play in the retainer ring.
5. Set the J 8001-3 to 0.
6. Pull up on the turbine shaft (502) while holding up the output carrier assembly with the J 28585 . End Play Specification: The correct end play is 0.102-0.559 mm (0.004-0.022 in).
7. Remove the tools from the transmission.
8. If the front end play measurement is incorrect, refer to the «Overrun Clutch Housing Selective Thrust Washer Specifications»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul__overrun-clutch-housing-selective-thrust-washer) . Choose a new selective thrust washer based on the original selective washer and the information contained in the table.
9. Correct the end play by changing the overrun clutch housing selective thrust washer.

Manual 2-1 Band Servo Assembly Disassemble

1. Remove the manual 2-1 band servo piston pin retainer ring (56).
2. Remove the manual 2-1 band servo piston pin (55).
3. Remove the manual 2-1 band servo piston seal (57).
4. Inspect the manual 2-1 band servo piston (58) for porosity, wear and seal ring groove damage.
5. Inspect the manual 2-1 band servo piston pin (55) and retainer ring (56) for wear and damage.

Manual 2-1 Band Servo Assembly Assemble

1. Install a new manual 2-1 band servo piston seal (57) onto the manual 2-1 band servo piston (58).
2. Install the manual 2-1 band servo piston pin (55) into the manual 2-1 band servo piston (58).
3. Install the manual 2-1 band servo piston pin retainer ring (56).

Manual 2-1 Band Servo Assembly Installation

1. Install the manual 2-1 band servo piston cushion spring (60).
2. Install the manual 2-1 band servo piston assembly (55-58).

Low and Reverse Band Servo Apply Piston Pin Check

Tools Required

1. J 21370-10 Band Apply Pin Gauge. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38737 Band Apply Pin Checking Tool. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the J 21370-10 into the low and reverse band servo pin bore.
2. Position the J 38737 over the low and reverse band servo bore with the hex hub facing the parking pawl linkage.
3. Fasten the J 38737 to the case with 2 low and reverse band servo cover bolts (61). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
4. Verify that the J 21370-10 moves freely in the J 38737 and in the low and reverse band servo pin bore.
5. Tighten the hex hub of the J 38737 . Tighten: Tighten the hex hub of the J 38737 to 34 N.m (25 lb ft).
6. Observe the lands on the J 21370-10 in order to determine which land is even with the top edge of the J 38737 . Note the letter (A, B or C) stamped on the J 21370-10 .
7. Refer to the Low and Reverse Band Servo Piston Pin Specification chart, in the «Transmission General Specifications»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul__transmission-general-specifications) , in order to determine the correct pin length to use.
8. Remove the tools.

Low and Reverse Band Servo Assembly Disassemble

1. Remove the low and reverse band servo piston seal (66) from the low and reverse band servo piston (65).
2. Inspect the low and reverse band servo piston seal (66) for nicks and cuts.
3. Remove the low and reverse band servo piston pin retainer ring (64).
4. Remove the low and reverse band servo piston pin (73).
5. Inspect the low and reverse band servo piston pin (73) for wear.
6. Remove the low and reverse band servo piston spring retainer (72).
7. Remove the low and reverse band servo piston spring (71).
8. Inspect the low and reverse band servo piston spring (71) for distortion.
9. Remove the low and reverse band servo piston spacer (87).
10. Remove the 1-2 accumulator piston (68).
11. Remove the low and reverse accumulator piston oil seal rings (67, 69).
12. Remove the 1-2 accumulator piston spring assembly (88).
13. Inspect the low and reverse band servo piston (65) and the 1-2 accumulator piston (68) for porosity and damage.
14. Inspect the low and reverse accumulator piston oil seal rings (67, 69) for nicks and cuts.

Low and Reverse Band Servo Assembly Assemble

1. Install the new low and reverse accumulator piston oil seal rings (67, 69) on the 1-2 accumulator piston (68). Lubricate the low and reverse accumulator piston oil seal rings (67, 69) with DEXRON® III automatic transmission fluid.
2. Install the 1-2 accumulator piston spring assembly (88) into the low and reverse band servo piston (65).
3. Install the 1-2 accumulator piston (68).
4. Assemble the following items, in order, onto the small diameter end of the correct low and reverse band servo piston pin (73): The low and reverse band servo piston spring retainer (72) The low and reverse band servo piston spring (71) The low and reverse band servo piston spacer (87) The low and reverse band servo piston (65)
5. Install the low and reverse band servo piston pin retainer ring (64).
6. Install the new low and reverse band servo piston seal (66). Lubricate the low and reverse band servo piston seal (66) with DEXRON® III automatic transmission fluid.

Low and Reverse Band Servo Assembly Installation

1. Install the low and reverse accumulator piston spring (74) into the transmission case.
2. Install the low and reverse band servo assembly (64-73).
3. Install the low and reverse band servo cover gasket (63).
4. Install the low and reverse band servo cover (62).
5. Install the 6 low and reverse band servo cover bolts (61). Tighten: Tighten the bolts to 24 N.m (18 lb ft) in an alternating pattern.

Third and Fourth Clutch Accumulator Housing Removal

1. Remove the 3rd and 4th clutch accumulator housing bolts (53).
2. Remove the 3rd and 4th clutch accumulator housing (51).
3. Remove the accumulator housing gasket (47). The accumulator housing gasket (47) may be stuck to the control valve body spacer plate (46).
4. Remove the 3rd clutch accumulator piston spring (50).
5. Remove the 4th clutch accumulator piston spring (49).
6. Remove the control valve body spacer plate (46).
7. Remove the control valve body gasket (45) from the control valve body spacer plate (46).

Third and Fourth Clutch Accumulator Housing Disassemble

1. Remove the 3rd clutch accumulator piston (405) from the 3rd and 4th clutch accumulator housing (51).
2. Remove the 3rd clutch accumulator piston seals (404, 406).
3. Inspect the 3rd clutch accumulator piston and seals for porosity, scoring, nicks, scratches and damage.
4. Remove the 4th clutch accumulator piston pin retainer ring (402).
5. Remove the 4th clutch accumulator piston (407) and pin (408).
6. Remove the 4th clutch accumulator piston pin (408) from the 4th clutch accumulator piston (407).
7. Remove the 4th clutch accumulator piston seal (404).
8. Inspect the 4th clutch accumulator piston, pin and seal for porosity, scoring, nicks, scratches and damage.

Third and Fourth Clutch Accumulator Housing Assemble

1. Install the 3rd clutch accumulator piston inner (406) and outer (404) seals. Lubricate the seals (404, 406) with DEXRON® III automatic transmission fluid.
2. Install the 3rd clutch accumulator piston (405) into the 3rd and 4th clutch accumulator housing (51).
3. Install the 4th clutch accumulator piston seal (404). Lubricate the seal (404) with DEXRON® III automatic transmission fluid.
4. Assemble the 4th clutch accumulator piston pin (408) with the 4th clutch accumulator piston (407).
5. Install the 4th clutch accumulator piston assembly.
6. Install the 4th clutch accumulator piston pin retainer ring (402).

Control Valve Body Assembly Disassemble

1. Remove the pressure control solenoid clamp bolt (310) and clamp (321).
2. Remove the pressure control solenoid assembly (320).
3. Inspect the pressure control solenoid assembly (320) for a plugged or damaged screen.
4. Remove the TCC PWM solenoid valve retainer (322).
5. Remove the TCC PWM solenoid valve assembly (323).
6. Remove the TCC regulator apply valve pin (303). Use a drill bit to remove the spring pin.
7. Remove the TCC regulator apply valve (324).
8. Remove the TCC regulator apply valve spring (325).
9. Inspect the TCC regulator apply valve (324) for porosity, scoring, and nicks.
10. Inspect the TCC regulator apply valve spring (325) for distortion.
11. Remove the actuator feed limit valve spring retainer (333).
12. Remove the actuator feed limit valve spring (327).
13. Remove the actuator feed limit valve (328).
14. Inspect the actuator feed limit valve (328) for porosity, scoring, and nicks.
15. Inspect the actuator feed limit valve spring (327) for distortion.
16. Remove the accumulator valve bore plug retainer pin (303).
17. Remove the accumulator valve bore plug (329).
18. Remove the accumulator valve spring (330).
19. Remove the accumulator valve (331).
20. Inspect the accumulator valve (331) and accumulator valve bore plug (329) for porosity, scoring, and nicks.
21. Inspect the accumulator valve spring (330) for distortion.
22. Remove the pressure control solenoid valve fluid filter assembly (302).
23. Inspect the pressure control solenoid valve fluid filter assembly (302) for damage.
24. Remove the low-reverse ball valve seat pin (318).
25. Remove the low-reverse ball valve seat (304).
26. Remove the low-reverse ball valve (305).
27. Inspect the low-reverse ball valve seat (304) and the low-reverse ball valve (305) for porosity, scoring, and nicks.
28. Remove the shift valve fluid filter bore plug pin (303).
29. Remove the shift valve fluid filter bore plug (316).
30. Remove the shift solenoid valve fluid filter assembly (317).
31. Inspect the shift solenoid valve fluid filter assembly (317) for damage.
32. Inspect the shift valve fluid filter bore plug (316) for porosity, scoring, and nicks.
33. Remove the 1-2 shift solenoid valve bolt (310).
34. Remove the 1-2 shift solenoid valve assembly (313).
35. Remove the 1-2 shift valve pin (303).
36. Remove the 1-2 shift valve (314).
37. Remove the 1-2 shift valve spring (315).
38. Inspect the 1-2 shift valve (314) for porosity, scoring, and nicks.
39. Inspect the 1-2 shift valve spring (315) for distortion.
40. Remove the 2-3 shift solenoid valve bolt (310).
41. Remove the 2-3 shift solenoid valve assembly (311).
42. Remove the 2-3 shift valve pin (303).
43. Remove the 2-3 shift valve (312).
44. Remove the 2-3 shift valve spring (309).
45. Inspect the 2-3 shift valve (312) for porosity, scoring, and nicks.
46. Inspect the 2-3 shift valve spring (309) for distortion.
47. Remove the 3rd-reverse ball valve seat pin (303).
48. Remove the reverse ball valve bushing (334).
49. Remove the 3rd-reverse ball valve (305).
50. Remove the 3rd ball valve bushing (335) and 3rd ball valve bushing seal (307).
51. Remove the 3-4 shift valve (308).
52. Remove the 3-4 shift valve spring (309).
53. Inspect the 3rd-reverse ball valve bushings (334, 335), the 3rd-reverse ball valve (305) and the 3-4 shift valve (308) for porosity, scoring, and nicks.
54. Inspect the 3-4 shift valve spring (309) for distortion.

Control Valve Body Cleaning and Inspection

1. Clean the control valve body (301) in clean solvent.
2. Dry the control valve body (301) using compressed air.
3. Inspect the control valve body casting for the following conditions: Porosity Cracks Interconnected passages Damaged machined surfaces

Control Valve Body Assembly Assemble

1. Install the 3-4 shift valve spring (309).
2. Install the 3-4 shift valve (308).
3. Install the 3rd ball valve bushing (335) and 3rd ball valve bushing seal (307).
4. Install the 3rd-reverse ball valve (305).
5. Install the reverse ball valve bushing (334).
6. Install the 3rd-reverse ball valve seat pin (303).
7. Install the 2-3 shift valve spring (309).
8. Install the 2-3 shift valve (312).
9. Install the 2-3 shift valve pin (303).
10. Install the 2-3 shift solenoid valve assembly (311).
11. Install the 2-3 shift solenoid valve bolt (310). Tighten: Tighten the bolt to 8 N.m (71 lb in).
12. Install the 1-2 shift valve spring (315).
13. Install the 1-2 shift valve (314).
14. Install the 1-2 shift valve pin (303).
15. Install the 1-2 shift solenoid valve assembly (313).
16. Install the 1-2 shift solenoid valve bolt (310). Tighten: Tighten the bolt to 8 N.m (71 lb ft).
17. Install the (317).
18. Install the shift valve fluid filter bore plug (316).
19. Install the shift valve fluid filter bore plug pin (303).
20. Install the low-reverse ball valve (305).
21. Install the low-reverse ball valve seat (304).
22. Install the low-reverse ball valve seat pin (318).
23. Install the pressure control solenoid valve fluid filter assembly (302).
24. Install the accumulator valve (331).
25. Install the accumulator valve spring (330).
26. Install the accumulator valve bore plug (329).
27. Install the accumulator valve bore plug retainer pin (303).
28. Install the actuator feed limit valve (328).
29. Install the actuator feed limit valve spring (327).
30. Install the actuator feed limit valve spring retainer (333).
31. Install the TCC regulator apply valve spring (325).
32. Install the TCC regulator apply valve (324).
33. Install the TCC regulator apply valve pin (303).
34. Install the TCC PWM solenoid valve assembly (323).
35. Install the TCC PWM solenoid valve retainer (322).
36. Install the pressure control solenoid valve assembly (320) with the electrical connector terminals pointing away from the control valve body.
37. Install the pressure control solenoid clamp (321).
38. Install the pressure control solenoid clamp bolt (310). Tighten: Tighten the bolt to 8 N.m (71 lb in).

J 25025-5 Guide Pin. See Special Tools and Equipment .

1. Install the J 25025-5 into the control valve body bolt hole where the manual shaft detent roller and spring assembly is mounted.
2. Install the control valve body gasket (45).
3. Install the control valve body spacer plate (46).
4. Install the accumulator housing gasket (47).
5. Install the 3rd clutch accumulator piston spring (50). This spring is the longer of the 2 accumulator springs.
6. Install the 4th clutch accumulator piston spring (49).
7. Install the 3rd and 4th clutch accumulator housing (51) onto the control valve assembly (44).
8. Install the 6 3rd and 4th clutch accumulator housing bolts (53). Tighten the bolts finger tight and start from one end of the accumulator housing toward the opposite end.
9. Tighten the 3rd and 4th clutch accumulator housing bolts (53) in the order shown. Tighten: Tighten the bolts to 11 N.m (97 lb in).
10. Remove the J 25025-5 .

Control Valve Body Assembly Installation

Tools Required

1. J 25025-5 Guide Pin. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the 8 control valve body ball check valves (54) into the case passages. Use J 36850 or equivalent in order to hold the control valve body ball check valves in place.
2. Install the TCC solenoid valve screen assembly (75) into the case.
3. Install the manual valve (319) into the control valve assembly.
4. Install the J 25025-5 into the transmission case.
5. Install the control valve body spacer plate gasket (48).
6. Install the control valve assembly (44). Attach the manual valve (319) to the detent lever (711) while installing the control valve assembly (44).
7. Install the transmission fluid pressure manual valve position switch (40).
8. Install the transmission fluid pressure manual valve position switch bolts (76) finger tight.
9. Tighten the bolts in the order shown. Tighten: Tighten the bolts to 11 N.m (97 lb in).
10. Remove the J 25025-5 .
11. Install the manual shift shaft detent spring assembly (41) and bolts (35).
12. Install the 2 wiring harness clamps (33) and bolts (35).
13. Install the lube oil pipe (39) with the short end into the control valve assembly.
14. Install the lube oil pipe retainer (37) and the bolt (35).
15. Install the remaining control valve body assembly bolts (35).
16. Tighten the control valve body assembly bolts in the order shown. Tighten: Tighten the bolts to 11 N.m (97 lb in).

Wiring Harness Installation

1. Install a NEW pass thru O-ring seal (36).
2. Install the wiring harness assembly (34) into the case.
3. Connect the wiring harness assembly (34) to the electrical components.
4. Place the wiring harness assembly (34) under the wiring harness clamps (33).

Transmission Oil Filter Assembly Installation

1. Lubricate the new filter neck seal assembly (32) with transmission fluid.
2. Install a new filter neck seal assembly (32) into the transmission case.
3. Install the transmission oil filter assembly (31) into the filter neck seal assembly (32).

Transmission Oil Pan Installation

1. Install the transmission oil pan gasket (29).
2. Install the transmission oil pan magnet (30) into the transmission oil pan (28).
3. Install the transmission oil pan (28).
4. Install the transmission oil pan bolts (27). Tighten: Tighten the bolts to 24 N.m (18 lb ft).

Speed Sensor Assembly Installation

1. Install the input and output speed sensors (22), (output speed sensor plug-4WD) into the transmission case.
2. Install the input and output speed sensor bolts (23). Tighten: Tighten the bolts to 11 N.m (97 lb in).

Case Extension Assembly Installation

Tools Required

1. J 38694 Extension Housing Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 38869 Rear Extension Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Install the prop shaft front slip yoke oil seal assembly (20) (model dependent) with the J 38869 or the J 38694 (for fixed yoke applications). Apply J 36850 or equivalent to the spring pocket of the seal.
2. Install the transmission output shaft yoke seal sleeve (682) and the output shaft seal (683) (for some models).
3. Install the output shaft seal (675) (for some models).
4. Install the bearing spacer (18), case extension ball bearing assembly (17) and the bearing retainer ring (16) (for some models).
5. Install the case extension seal (15) onto the case extension assembly (19).
6. Install the case extension assembly (19) onto the transmission case.
7. Install the case extension bolts (21). Tighten: Tighten the bolts to 34 N.m (25 lb ft).

J 21366 Converter Holding Strap. See Special Tools and Equipment .

1. Rotate the transmission so the converter housing is facing up.
2. Install the torque converter assembly (1). Rotate the torque converter assembly (1) in order to engage the turbine shaft, the stator shaft, and the lugs onto the oil pump drive gear.
3. Install the J 21366 in order to hold the torque converter assembly (1) in place while moving the transmission assembly. Remove the J 21366 prior to installing the transmission into the vehicle.

Holding Fixture Removal

Tools Required

1. J 3289-20 Holding Fixture Base Assembly. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
2. J 8763-02 Transmission Holding Fixture. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .
3. J 38655 Holding Fixture Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-trans/#automatic-transmission-4l80-e4l85-e-overhaul) .

1. Remove the transmission assembly and the J 8763-02 from the J 3289-20 .
2. Remove the J 8763-02 and the J 38655 .

Park or Neutral - Engine Running

When you start the vehicle, the oil pump generates fluid flow from the transmission sump through the filter and into the pump. Filtered transmission fluid is directed to the pressure regulator valve.

Scheme 104

Reverse

When you move the gear selector lever to the Reverse position, the manual valve blocks the line fluid pressure from entering the Drive, D321, D21 and Lo fluid circuits. These fluids exhaust at the manual valve. The manual valve allows the line fluid pressure to enter the Reverse, PRN, PRND43, and PRND4 hydraulic circuits.

Scheme 105

Overdrive Range, First Gear

When you move the gear selector lever to the Overdrive position, the manual valve is repositioned in order to allow line pressure to flow in its respective circuits.

Scheme 106

Overdrive Range, Second Gear

In order to obtain second gear, the PCM receives input signals from the transmission speed sensors (input and output), the Throttle Position (TP) Sensor, and from other engine sensors. These signals determine when to de-energize the 1-2 Shift Solenoid (SS) Valve.

Scheme 107

Overdrive Range, Third Gear - Torque Converter Clutch (TCC) Applied

In order to obtain third gear, the PCM receives input signals from both speed sensors, from the TP Sensor, and from other engine sensors. These signals determine when to energize the 2-3 Shift Solenoid (SS) Valve.

Scheme 108

Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied

In order to obtain fourth gear, the PCM receives input signals from both speed sensors, from the TP Sensor, and from other engine sensors. These signals determine when to energize the 1-2 Shift Solenoid (SS) Valve.

Scheme 109

Overdrive Range, 4-3 Downshift

In order to obtain the 4-3 downshift, the PCM receives an input signal from the TP Sensor at increased throttle openings. This causes the PCM to de-energize the 1-2 Shift Solenoid (SS) Valve.

Scheme 110

Overdrive Range, 3-2 Downshift

In order to obtain the 3-2 downshift, the PCM receives an input signal from the TP Sensor at increased throttle openings. This causes the PCM to de-energize the 2-3 Shift Solenoid (SS) Valve.

Scheme 111

Manual Third Gear

Manual Third can be used in order to increase the performance of the vehicle by allowing higher engine RPM for more torque. Manual Third will also provide vehicle engine compression braking when descending slight grades. Manual Third can be selected at any vehicle speed. The transmission will downshift into third gear at any vehicle speed.

Scheme 112

Manual Second Gear

Use the Manual 3-2 downshift in order to provide increased engine braking over Manual Third. Move the shift selector from the Manual Third position to the Manual Second position. You can select Manual Second at any vehicle speed or from any gear range in order to downshift the transmission into second gear.

Scheme 113

Manual First Gear

Use Manual First for maximum engine braking when the car is descending steep grades. Select Manual First at any vehicle speed. However, the transmission will first operate in Manual First - Second Gear condition until the vehicle speed slows sufficiently.

Scheme 114

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Scheme 123

Special Tools

Special Tools Illustration Tool Number/Description J 3289-20 Holding Fixture Base Assembly J 6116-01 Rear Gear Holding Fixture J 6125-1B Slide Hammer J 6129 Handle J 7057 Dial Indicator Plunger Extension J 8001 Dial Indicator Set J 8763-02 Transmission Holding Fixture J 21362-1 Direct and Forward Clutch Piston and Inner Seal Protector J 21363 Intermediate Clutch Inner Seal Protector J 21364-A Rear Gear Holding Fixture Adapter J 21366 Converter Holding Strap J 21368 Pump Body and Cover Alignment Band J 21370-10 Band Apply Pin Gauge J 23093 Center Support Alignment Tool J 23129 Universal Seal Remover J 23327 Clutch Spring Compressor J 24396 Intermediate Clutch Pack Alignment Tool J 25018-A Clutch Spring Compressor Adapter J 25025-B Dial Indicator Post and Guide Pin Set J 25025-1 Guide Pins J 25025-5 Guide Pins J 26900-13 Magnetic Indicator Base J 28585 Snap Ring Remover J 36850 Assembly Lubricant J 38358-A Forward Clutch Assembly Remover/Installer J 38655 Holding Fixture Adapter J 38693 Oil Pump Seal and Rear Lube Seal Installer J 38694 Extension Housing Seal Installer J 38695 Direct Clutch Spiral Retaining Ring Installer J 38729 Overrun Clutch Piston Seal Protector J 38731-1 Fourth Clutch Piston and Housing Seal Protector J 38731-2 Fourth Clutch Piston and Housing Seal Protector J 38731-3 Fourth Clutch Piston and Housing Seal Spacer J 38732-1 Direct and Forward Clutch Piston and Outer Seal Protector J 38733 Direct Clutch Assembly Remover/Installer J 38734 Intermediate Spring Compressor Adapter J 38736-1 Turbine Shaft Seal Installer J 38736-2 Turbine Shaft Seal Installer J 38736-3 Turbine Shaft Seal Sizer J 38736-4 Turbine Shaft Seal Sizer J 38736-5 Turbine Shaft Seal Pusher J 38736-6 Turbine Shaft Seal Pusher J 38737 Band Apply Pin Checking Tool J 38868-A Output Shaft Assembly Remover/Installer J 38869 Rear Extension Seal Installer J 38882 Fourth Clutch Spring and Retainer Assembly Adapter J 39195 Converter End Play Check Tool J 39919-1 Center Support Thread Reamer J 39919-2 Center Support Gage Pin J 41505 Output Shaft Seal Installer J 45053 Universal Clamp Press

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Scheme 141

See also:
• Special Tools and Equipment
• Low and Reverse Band Servo Apply Piston Pin Check
• Torque Converter End Play Inspection
• Transmission General Specifications
• End Play Specifications
• Output Shaft Selective Thrust Washer Specifications
• Overrun Clutch Housing Selective Thrust Washer Specifications