Automatic Transmission - 4l60-e/4l65-e - Overhaul Chevrolet Chevy Express G3500

Fastener Tightening Specifications

Fastener Tightening Specifications

Fluid Capacity Specifications

Fluid Capacity - Approximate

End Play Specifications

Transmission End Play Washer Selection Chart

Low and Reverse Clutch Spacer Plate Selection

Low and Reverse Clutch Plate Selection Table

Forward Clutch Backing Plate Selection

Forward Clutch Backing Plate Selection

Third and Fourth Clutch Backing Plate Selection

3rd and 4th Clutch Backing Plate Selection Table

Reverse Input Clutch Backing Plate Selection

Reverse Input Clutch Backing Plate Selection Table

Oil Pump Rotor and Slide Measurement

Oil Pump Rotor and Slide Measurement

Secondary Fluid Pump Assembly Specifications (M33 Only)

Secondary Fluid Pump Assembly Specifications (M33 Only)

Torque Converter End Play Inspection

Torque Converter End Play Check

Scheme 1

2-4 Servo Pin Selection

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Do Not Use Air Tools

Note. Do not use air powered tools in order to disassemble or assemble any vehicle component. Bolt torques are vital to diagnosis. You can detect bolt torques only when using hand tools. Improper bolt torques can contribute to vehicle repair problems.

Tools Required

J 8763-02 Holding Fixture and Base. See Special Tools and Equipment .

Installation Procedure

1. Install the J 8763-02 onto the transmission.
2. Install the J 8763-02 into the base.

Torque Converter Assembly Removal

Scheme 22

Remove the torque converter.

Scheme 23

Rotate the transmission so that the converter housing is up. Allow the transmission fluid to drain from the case extension.

J 41510 T-50 Plus Bit. See Special Tools and Equipment .

Removal Procedure

1. Remove the converter housing bolts (94). Use the J 41510 .
2. Remove the converter housing (102).

J 29714-A Servo Cover Compressor. See Special Tools and Equipment .

1. Install the J 29714-A .
2. Tighten the J 29714-A bolt to compress the servo cover.
3. Remove the servo cover retaining ring (29) and the J 29714-A .
4. Remove the servo cover (28) and O-ring seal (27). If the servo cover seems to be hung up on the seal, cut and remove the O-ring seal before removing the cover.
5. Remove the 2-4 servo assembly.

J 33037 2-4 Intermediate Band Apply Pin Gage. See Special Tools and Equipment .

Checking Procedure

1. Disassemble the 2-4 servo assembly. If necessary, refer to «2-4 Servo Disassemble»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. Install the band apply pin (13) and the J 33037 (1).
3. Install the servo cover retaining ring (29) to secure the tool.
4. Apply 11 N.m (98 lb in) torque. If the white line appears in the gage slot (1), the pin length is correct.
5. If a new pin is needed, refer to «2-4 Servo Pin Selection»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) in order to determine correct pin length.

J 29837-A Output Shaft Support Fixture. See Special Tools and Equipment .

1. Remove the sensor retaining bolt (35).
2. Remove the speed sensor (36) and O-ring seal (37).
3. Remove the case extension bolts (32).
4. Remove the case extension (31) and the case extension to case seal (30).
5. Remove the output shaft sleeve (690) and the output shaft O-ring seal (691). Not all models use an output shaft sleeve (690) and O-ring seal (691).
6. Install the J 29837-A . If the J 29837-A is not used, the output shaft (687) may fall free when the input carrier retaining ring is removed.

Pan and Filter Assembly Removal

1. Remove the transmission oil pan screws (76).
2. Remove the transmission oil pan (75) and the transmission oil pan gasket (73).
3. Remove the transmission oil filter assembly (72).
4. The filter may help in diagnosis. Cut away the top portion of the plastic filter housing and remove. Inspect the filter for the presence of the following items which may indicate wear or corrosion: Clutch material Bronze slivers indicating bushing wear Steel particles
5. Remove the oil filter seal (71).

Secondary Fluid Pump Assembly Removal (M33 Model Only)

1. Disconnect the electrical connector from the secondary fluid pump (108).
2. Remove retaining bolts (109 and 110) from the secondary fluid pump (108).
3. Remove the secondary fluid pump (108).

Valve Body and Wiring Harness Removal

1. Remove all electrical connectors (1-6) from the electrical components.
2. Remove the torque converter clutch (TCC/PWM) pulse width modulation retainer clip (395).
3. Remove the TCC/PWM solenoid (396).
4. Remove the TCC solenoid bolts (68).
5. Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so that it hangs over the side of the transmission.
6. Remove the transmission fluid pressure (TFP) manual valve position switch assembly bolts (62, 70).
7. Remove the TFP manual valve position switch (69).
8. Remove the manual detent spring bolt (64).
9. Remove the manual detent spring assembly (63).
10. Remove all valve body bolts (62).
11. Remove the fluid level indicator stop bracket (93) - model dependent.
12. Lift the valve body carefully so that the checkballs remain on the spacer plate in the correct location. While lifting the valve body, disconnect the manual valve link from the manual valve.
13. Remove the 7 valve body checkballs (2-6, 8, 12).
14. Remove the accumulator cover bolts (58, 59 or 117, 118).
15. Remove the 1-2 accumulator cover and pin assembly (57 or 116).
16. Disassemble the 1-2 accumulator assembly (54, 56, 57, 104).
17. Remove the spacer plate support bolts (77).
18. Remove the spacer plate support (53 or 113).
19. Remove the valve body gasket (52), the valve body spacer plate (48) and the case gasket (47). Discard gaskets. Do not reuse.
20. Remove the 3-4 accumulator spring (model dependent) and the 3-4 accumulator piston.
21. Remove the case checkball (#1).

Scheme 24

Remove the O-ring (618) from the turbine shaft. O-Ring location is model dependent.

Transmission End Play Check

Tools Required

1. J 25022 End Play Fixture Adapter (245 mm and 258 mm). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 34725 End Play Checking Adapter (298 mm). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 43205 End Play Fixture Adapter (300 mm). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 24773-A Oil Pump Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
5. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
6. J 25025-7A Dial Indicator Mounting Post. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install an end play fixture adapter. Use J 25022 for a 245 mm and 258 mm turbine shaft (1). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) . Use J 34725 for a 298 mm turbine shaft (2). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) . Use J 43205 for a 300 mm turbine shaft (3). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. Install the J 24773-A .
3. Remove an oil pump bolt.
4. Install J 25025-7A (or a 278 mm or 11 in bolt) and lock nut.
5. Install J 8001 .
6. Set the J 8001 to zero.
7. Pull up on J 24773-A . Proper end play should be 0.13-0.92 mm (0.005-0.036 in).
8. The selective washer (616), which controls the end play, is located between the input housing (621) and the thrust bearing (615) on the oil pump hub. If the end play measurement is incorrect, refer to «End Play Specifications»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__end-play-specifications) . Choose a new selective washer (616) based on the original selective washer and the information contained in the table. If the dial indicator shows no end play, the selective washer (616) and thrust bearing (615) may have been misassembled.
9. Correct the end play by changing the selective washer (616).

Oil Pump Removal

Tools Required

1. J 37789-A Oil Pump Remover/Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 39119 Oil Pump Remover/Installer Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Remove all pump bolts (2).
2. Install J 39119 over stator shaft until it locks under splines.
3. Install J 37789-A .
4. To prevent slipping, securely fasten the J 37789-A around the J 39119 by tightening the bolt (1) with a wrench.
5. Turn the T-handle on top of J 37789-A .
6. Lift the pump out of the case.
7. Some Models use an external fluid pump seal (5) that can be removed after the pump is removed.
8. Remove the pump cover to case gasket (6).

2-4 Band, Input Clutches, Input Gear Set Removal

1. Remove the band anchor pin.
2. Remove the input housing and shaft assembly and the reverse input clutch housing and drum assembly.
3. Remove the 2-4 band assembly (602).

Reaction Gear Set Removal

1. Use snap ring pliers remove the output shaft to input carrier retainer (661).
2. Remove the input carrier assembly (662) and remove the bearing assembly (663).
3. Remove the input internal gear (664) and the reaction carrier shaft assembly (666).
4. Remove the thrust washer (669a or 669b) and the reaction sun shell (670).

J 29837-A Output Shaft Support Fixture

1. Remove the reaction sun gear (673) and the thrust washer (674).
2. Remove the low and reverse support retainer ring (676).
3. Remove the J 29837-A .
4. Push on the output shaft (687) in order to loosen the low and reverse clutch support (679).
5. Remove the low and reverse clutch support (679).
6. Remove the output shaft (687).
7. Remove the low and reverse clutch support retainer spring (680).
8. Remove the reaction carrier assembly (681).
9. Remove the following components: The low and reverse clutch fiber plate assembly (682C) The low and reverse clutch steel plates (682D) The low and reverse clutch selective plate (682B) The low and reverse clutch waved plate (682A)
10. Remove the following components: The thrust bearing assembly (reaction carrier support) (683) The internal reaction gear (684) The internal reaction gear support (685) The reaction gear support bearing (692)

Inner Manual Linkage Removal

1. Remove the following parts: Hex head nut (90) Manual valve link (89) Detent lever (88) Parking lock actuator assembly (85) Manual shaft retainer (83) Manual shaft (84)
2. Remove the manual shaft seal (82) with a screwdriver.
3. Remove the following components: The parking lock bracket bolt (87) The parking lock bracket (86)

Low and Reverse Clutch Piston Removal

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 34627 Snap Ring Remover and Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 42628 Disc. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install the J 23327-1 and the J 42628 .
2. Tighten the J 23327-1 .
3. Remove the low and reverse clutch retainer ring (693) using the J 34627 .
4. Remove the low and reverse clutch spring assembly (694).
5. Blow compressed air into the case passage to remove the low and reverse clutch piston (695). (1) LO Feed Passage (2) REV Feed Passage

Case Assembly Inspection

1. Inspect the spacer plate to case gasket for witness marks. The witness marks should be complete. Incomplete witness marks may come from an uneven case surface or from cross channel leaks.
2. Using compressed air, blow into all of the case fluid passages (3, 7, 8, 11, 16, 18, 26, 29, 37, 45) to ensure that all case fluid passages are clear of any obstruction.
3. Inspect the 2-4 servo bore, the 3rd accumulator retainer and ball assembly (40), the orifice cup plug (11) in the servo bore, and the 2nd apply piston pin bore for any of the following conditions: Porosity Burrs Debris Any other damage
4. Inspect the 3-4 accumulator bore and the orifice cup plug (38) for any of the following conditions: Porosity Burrs Blockage Any other damage
5. Inspect all bolt holes for thread damage. Use heli-coil to repair damaged threads.
6. Inspect the cooler connectors for damage and proper torque. Specification: Cooler connector torque should be 38 N.m (28 lb ft)

J 29714-A Servo Cover Compressor. See Special Tools and Equipment .

1. Install the 2-4 servo into the case.
2. Install oil pan with only four bolts to align pan to case.
3. Use the J 29714-A in order to compress the servo cover.
4. Install the servo cover retaining ring.
5. Remove oil pan.
6. Pour solvent into the accumulator bore until the channel is filled. Watch for leaks in the case channel.
7. If leakage from the oval shaped hole is observed, replace the third accumulator retainer and ball assembly.

Third Accumulator Retainer and Ball Replacement

1. Remove the third accumulator retainer and ball assembly, using a 6.3 mm (0.25 in) #4 screw extractor.
2. Scribe a mark at 42 mm (1.653 in) on a 9.5 mm (0.375 in) diameter metal rod. The scribe mark is used to gage the proper depth of the third accumulator retainer and ball assembly.
3. Perform the following functions: Line up the oil feed slots in the third accumulator retainer and ball assembly (40) with the servo bore. Using the 9.5 mm (0.375 in) diameter metal rod, install the third accumulator retainer and ball assembly.
4. Ensure that the third accumulator retainer and ball assembly and the scribe mark on the rod are flush with the case surface.
5. Check the third accumulator retainer and ball assembly (40) for alignment. The slot in the retainer must be completely open in the servo bore.

Tools Required

1. J 8092 Driver Handle
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Remove the case rear oil seal (106) (Y-car Only).
2. Remove the case bushing (7) using J 8092 and J 34196-10 which is part of kit J 34196-B .

Tools Required

1. J 8092 Driver Handle
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 42198 Case Rear Oil Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install a case bushing (7) using J 8092 and J 34196-10 which is part of kit J 34196-B .
2. Install a case rear oil seal (106) (Y-car Only) using J 42198 .

Scheme 25

Install a new manual shaft seal (82).

Low and Reverse Clutch Piston Installation

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 34627 Snap Ring Remover and Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 36850 Transjel Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install the transmission (low and reverse clutch outer, center, inner) seals (696) on the low and reverse clutch piston (695).
2. Lubricate the seals with assembly lubricant J 36850 or an equivalent.
3. Install the low and reverse clutch piston (695) into the case. The notch in the piston must be aligned with the parking brake pawl window, in the case.
4. Install the low and reverse clutch spring assembly (694). Using the J 23327-1 , compress the low and reverse clutch spring assembly (694). Using J 36850 install the low and reverse clutch retainer ring (693).

Inner Manual Linkage Installation

1. Install the parking lock bracket (86).
2. Install the parking lock bracket bolt (87). Tighten: Tighten the bolt to 31 N.m (23 lb ft).
3. Inspect the following items: The parking brake pawl (81) for damage or cracks The parking pawl return spring (80) for being broken or missing
4. Inspect the following items: The manual shaft retainer (83) for damage or cracks The manual shaft (84) for damage or burrs The parking lock actuator assembly (85) for damage The inside detent lever (88) for damage or cracks The manual valve link (89) for damage The hex head nut (90) for damage or stripped threads
5. Install the following items: The inside detent lever (88) The parking lock actuator assembly (85) The manual shaft (84) (model dependent) The manual shaft retainer (83) The hex head nut (90) The manual valve link (89) Tighten: Tighten the nut to 31 N.m (23 lb ft).

Reaction Gear and Carrier Inspection

1. Inspect the reaction carrier/support thrust bearing assembly (683) for wear or damage.
2. Inspect the reaction gear support to case bearing (692) for wear or damage.
3. Inspect the internal reaction gear (684) and the internal reaction gear support (685) for proper assembly, stripped splines, cracks, teeth, and lug damage.
4. Check the reaction carrier pinion end play. The end play must not exceed 0.61 mm (0.024 in). Inspect the reaction carrier for the following conditions: Pinion gear damage Proper pinion staking Excessive pinion washer wear Keystoned pinion gears
5. Ensure that the pinions turn freely.
6. Inspect the reaction carrier captive thrust bearing for wear or damage. Without touching the pinion gears, place a bushing or an output shaft sleeve (690) onto the bearing race, and turn it with the palm of your hand. Any imperfections will be felt through the bushing.

J 36850 Transjel Lubricant. See Special Tools and Equipment .

1. Install the reaction carrier/support thrust bearing assembly (683) into the internal reaction gear support (685).
2. Install the reaction gear support to case bearing (692) onto the internal reaction gear support (685). Retain the bearing using J 36850 or equivalent.
3. Install the internal reaction gear (684) and the internal reaction gear support (685) into the case.
4. Install the reaction carrier assembly (681) into the internal reaction gear.

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 26900-13 Magnetic Indicator Base. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the low and reverse clutch plates for the following conditions: Composition material wear Composition material heat damage Composition material delamination Steel plates heat damage Steel plates surface finish damage
2. Stack the low and reverse clutch plate assembly on a flat surface in the following order: One waved plate (682A) Five fiber plate assemblies (682C) and four steel plates (682D), starting with one fiber plate assembly and alternating with steel Low and reverse clutch support (679)
3. Using the J 8001 (1) and the J 26900-13 (2), measure the height of the clutch pack from the work surface to the top of the low and reverse clutch support (679).
4. Refer to «Low and Reverse Clutch Spacer Plate Selection»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__low-and-reverse-clutch-spacer-plate) in order to select the proper thickness of the low and reverse clutch selective spacer plate (682B).
5. Install the proper selective spacer plate (682B) between the wave plate (682A) and the first fiber plate assembly (682C), with the identification side up. The overall height for the clutch pack including the selective spacer plate should be 29.22-29.90 mm (1.15-1.18 in).

Low and Reverse Clutch Plates Installation

1. Install the waved plate.
2. Install the correct selective spacer plate (from the selection procedure).
3. Install the five fiber plate assemblies and four steel plates, starting with one fiber plate assembly and alternating with steel.
4. Index the steel plate splines in the case as shown.

Low and Reverse Clutch Support Disassemble

1. Remove the low and reverse roller clutch race (675) from the low and reverse clutch support (679). Inspect the race for damage and surface finish.
2. Remove the low and reverse roller retainer ring (677) and the low and reverse roller clutch assembly (678). Inspect the roller clutch assembly for damaged rollers and broken springs.
3. Inspect the low and reverse clutch support (679) for loose cam and cam surface finish. Check the support for cracks and damaged lugs.
4. Clean and install the low and reverse roller clutch assembly (678) into the low and reverse clutch support (679). Install the low and reverse retainer ring (677).

Low and Reverse Clutch Support Installation

1. Install the low and reverse roller clutch race (675). Simultaneously, turn and insert the race.
2. Rotate the race in order to verify proper operation. The race should only rotate in one direction.
3. Install the (680) into the case.
4. Install the low and reverse clutch support (679), roller clutch and roller clutch race (675) assembly into the case. Position the hub side down during the installation.
5. Install the low and reverse support retainer ring (676) into the case.

Reaction Sun Gear Installation

Tools Required

1. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 8092 Universal Driver Handle - 3/4 in

1. Inspect the reaction sun gear (673) for the following defects: Nicks Scores Damaged spline or teeth A worn bushing (672) A loose or weak retaining ring (671)
2. If the reaction sun gear bushing (672) needs replacement, use J 34196-1 which is part of kit J 34196-B with J 8092 to remove the reaction sun bushing (672) from the reaction sun gear (673).
3. Using J 34196-1 which is part of kit J 34196-B with J 8092 , install a new reaction sun bushing (672) into the reaction sun gear (673).
4. Install the reaction sun gear (673) into the reaction carrier.
5. Install the thrust washer (674) with the tangs pointing down. Index the tangs of the thrust washer with the splines of the low and reverse roller clutch race.

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 7004-A Universal Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 23907 Slide Hammer with Bearing Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 25019-14 Stator Pump Bushing Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
5. J 29369-2 Bushing and Bearing Remover 2-3 in. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
6. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Remove the reaction carrier shaft/internal gear retainer (668) and the reaction carrier shaft (666) from the input internal gear (664).
2. Inspect the reaction carrier shaft (666) and the input internal gear (664) for the following defects: Scoring Cracking Damaged or worn bushings A cracked shaft A damaged spline Damaged gear teeth
3. Using J 29369-2 with J 23907 , remove the reaction carrier shaft front bushing (665).
4. Using J 25019-14 with J 7004-A , remove the reaction carrier shaft rear bushing (667).

1. Using J 34196-3 which is part of kit J 34196-B with J 8092 , install a new reaction carrier shaft front bushing (665).
2. Using J 34196-3 which is part of kit J 34196-B with J 8092 , install a reaction carrier shaft rear bushing (667).

J 36850 Transjel Lubricant. See Special Tools and Equipment .

1. Install the reaction sun shell (670) into the reaction sun gear.
2. Depending on model, install either a thrust bearing (669A) or thrust washer (669B) as follows: Install thrust washer (669B), tangs down into the holes in the reaction sun shell. Install the thrust bearing (669A) using J 36850 onto the reaction carrier shaft, tangs up, towards the shaft.
3. Install the input internal gear (664) and reaction carrier shaft (666) assembly into the sun gear shell. Index the reaction carrier shaft spline into the reaction carrier.
4. Install the input carrier to reaction shaft thrust bearing assembly (663).

Tools Required

1. J 8433 Two Jaw Puller. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 21427-A Speedometer Gear Puller Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 36352 Speed Sensor Rotor Installer Kit. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the internal transmission speed sensor rotor (699) for cracks or damaged teeth.
2. Inspect all splines on the output shaft (687) for cracks or damaged splines.
3. Remove the output shaft seal (691) and the output shaft sleeve (690) (model dependent) 2WD units only.
4. If the internal speed sensor rotor (699) is damaged, replace it.
5. Using J 8433 with J 21427-01 , remove the internal speed sensor rotor (699) from the output shaft (687).

1. Slip a new internal speed sensor rotor (699) over the output shaft splines.
2. Install the J 36352-4 in the groove on the output shaft (687).
3. Place the J 36352-6 on the output shaft (687). Press on the J 36352-6 until it contacts the J 36352-4 in the window (the J 36352-4 will be a positive stop for the J 36352-6 ).

J 29837-A Output Shaft Support Fixture. See Special Tools and Equipment .

1. Install the output shaft (687).
2. Install the J 29837-A .

Input Carrier Inspection

1. Check the input carrier pinion end play. The end play must not exceed 0.61 mm (0.024 in).
2. Inspect the input carrier for pinion gear damage, proper pin stake and keystoned pinion gears. Pinions must rotate freely.

Tools Required

1. J 8092 Universal Driver Handle - 3/4 in - 10
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

Scheme 26

Using J 34196-5 which is part of kit J 34196-B with J 8092 , remove the input sun gear front bushing (657) and rear bushing (659).

1. Using J 34196-4 which is part of kit J 34196-B with J 8092 , install the input sun gear front bushing (657).
2. Using J 34196-6 which is part of kit J 34196-B with J 8092 , install the input sun gear rear bushing (659).

Input Carrier Inspection and Installation

1. Inspect the input carrier captive thrust bearing assembly. To check the captive thrust bearing in the input carrier (662) for wear, place a bushing or an output shaft sleeve (690) onto the bearing race and turn it with the palm of your hand. Do not touch the pinion gears. Any imperfections will be felt through the bushing.
2. Install the input carrier assembly (662) onto the output shaft. The carrier assembly can be either a 4 or 5 pinion design, depending on model.
3. Install a new output shaft to input carrier retainer (661).
4. Remove the J 29837-A .

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 23456 Booster and Clutch Pack Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Remove the reverse input clutch housing and drum assembly (605) from the input clutch assembly (621).
2. Remove the stator shaft/selective washer bearing assembly (615).
3. Remove the selective thrust washer (616).
4. Remove the 3rd and 4th clutch backing plate retainer ring (656).
5. Remove all 3rd and 4th clutch plates (653-655).
6. Remove the 3-4 clutch boost spring assemblies (600).
7. Remove the forward clutch backing plate retainer ring (651).
8. Remove the forward clutch selective backing plate (650).
9. Remove the forward clutch sprag assembly.
10. Remove all forward clutch plates (646, 648, 649A, 649B).
11. Remove the input sun gear bearing assembly (637).
12. Remove the input housing to output shaft seal (636).
13. Remove all overrun clutch plates (645A, 645B).
14. Install the J 23327-1 and the J 25018-A .
15. Compress the overrun clutch spring, using the J 23456 .
16. Remove the overrun clutch spring retainer snap ring (635).
17. Remove the J 23327-1 and the J 25018-A .
18. Remove the overrun clutch spring assembly (634).
19. Remove the overrun clutch piston (632).
20. Remove the forward clutch piston (630).
21. Remove the forward clutch housing (628).
22. Remove the 3rd and 4th clutch spring assembly (626).
23. Remove the 3rd and 4th clutch apply ring (625).
24. Remove the 3rd and 4th clutch piston (623).

Input Housing and Shaft Assembly Inspection

1. Inspect the input housing and shaft assembly for the following items: Porosity Spline wear Three turbine shaft checkballs Retainer and checkball assembly (620) Orificed cup plug (698) Lube hole cracks
2. Inspect the turbine shaft oil seal ring grooves for damage or burrs. The oil seal rings (619) must fit loose into the ring grooves.
3. Inspect the oil feed passages for obstructions.
4. Apply compressed air into the passages indicated.

Input Housing and Shaft Assembly Assemble

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 23456 Booster and Clutch Pack Compressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 26744-A Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
5. J 29882 Overrun Clutch Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
6. J 29883 Forward Clutch Seal Protector. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install a new input to forward clutch housing O-ring seal (622).
2. Inspect the 3rd and 4th clutch piston (623) for the following conditions: Porosity or damage Seal damage
3. Install the 3rd and 4th clutch piston (623) into the input housing.
4. Inspect the forward clutch housing (628) for the following conditions: Proper check ball operation Damage or distortion Burrs in the seal areas Cracks
5. Inspect the forward clutch piston for the following conditions: Porosity or damage Seal damage Apply leg damage
6. Install the forward clutch piston (630) into the forward clutch housing (628).
7. Install the 3rd and 4th spring assembly (626) into the 3rd and 4th clutch apply ring (625).
8. Install the forward clutch housing (628) and forward clutch piston (630) into the 3rd and 4th apply ring (625).
9. Install the J 29883 on the input housing.
10. Install the 3rd and 4th clutch apply ring and the forward housing and piston assembly using the following procedure: Hold the assembly by the 3rd and 4th clutch apply ring (625) legs during installation. Do not let the forward clutch piston (630) separate from the forward clutch housing. Firmly seat the assembly.
11. Remove the J 29883 from the input housing.
12. Inspect the overrun clutch piston (632) for the following conditions: Porosity or damage Seal damage Overrun clutch ball proper operation
13. Install the J 29882 on the input housing.
14. Install the overrun clutch piston (632) into the input housing.
15. Remove the J 29882 from the input housing.
16. Using the J 26744-A , carefully install the overrun clutch piston outer seal.
17. Install the overrun clutch spring (634) assembly.
18. Install the J 23327-1 and the J 25018-A , and compress the overrun clutch spring assembly using J 23456 .
19. Install the overrun clutch spring retainer snap ring (635).
20. Remove the J 23327-1 and the J 25018-A .

Scheme 27

Install a new input housing to output shaft seal (636).

Overrun Clutch Installation

1. Inspect the fiber plate assemblies (645B) and the steel plates (645A) for the following defects: Damaged tangs Delamination Excessive wear Wear or heat damage
2. Install the overrun clutch plates into the input housing starting with a steel plate (645B) and alternating with fiber plate assemblies (645A).
3. Index the plates in the input housing with the wide notches remaining open.
4. Install the input sun gear bearing assembly (637) into the input housing.

Forward Clutch Sprag Disassemble

1. Remove the overrun clutch hub retaining snap ring (638).
2. Remove the overrun clutch hub (639).
3. Remove the forward sprag clutch inner race and input sun gear assembly (640).
4. Remove the sprag assembly retainer rings (643).
5. Remove the forward sprag assembly from the forward clutch outer race (644).

Forward Clutch Sprag Assemble

1. Inspect the forward sprag assembly (642) for the following conditions: Wear or damage Weak or broken springs
2. Inspect the forward clutch outer race (644) for the following conditions: Race wear or damage Spline wear Surface finish damage
3. Install the forward sprag assembly (642) into the forward clutch outer race (644).
4. Inspect the sprag assembly retainer rings (643) for wear or damage.
5. Install the sprag assembly retainer rings (643) into the forward clutch sprag assembly (644).
6. Inspect the forward sprag clutch inner race and input sun gear assembly (640) for the following conditions: Damaged spline or gear teeth Ring groove damage Surface finish damage Loose retainer Wear Cracks
7. Install the forward sprag clutch inner race and input sun gear assembly (640) into the forward sprag and outer race assembly.
8. Inspect the overrun clutch hub (639) for the following conditions: Spline damage Plugged lubrication holes Damaged tangs Cracks
9. Install the overrun clutch hub (639) onto the sprag clutch inner race and input sun gear assembly (640).
10. Install the overrun clutch hub retaining snap ring (638).
11. Test the forward clutch sprag assembly for proper operation. Position the forward clutch sprag assembly with the input sun gear facing up. IMPORTANT: The sun gear should only rotate in a counterclockwise direction. Hold the forward sprag clutch outer race with one hand and rotate the input sun gear with the other hand.
12. Install the forward clutch sprag and input sun gear assembly into the input clutch housing.
13. Index the overrun clutch hub into the overrun clutch plates.

Forward Clutch Assembly Assemble

1. Inspect the forward clutch waved plate (648), the apply plate (646), the fiber plate assemblies (649B), the steel plates (649A) and the selective backing plate (650) for the following conditions: Damaged tangs Delamination Excessive wear Heat damage Flatness Surface finish damage Burrs and nicks
2. Install the forward clutch apply plate (646).
3. Install the forward clutch waved plate (648).
4. Install the forward clutch steel plates (649A) and alternate with the fiber plate assemblies (649B).
5. Install the forward clutch selective backing plate (650).
6. Install the forward clutch backing plate retainer ring (651).

Forward Clutch Piston Travel Check

1. Use feeler gauges to check the forward clutch plate travel. Check travel between the forward clutch backing plate retainer ring (651) and the forward clutch selective backing plate (650). The forward clutch plate travel should be: Specification: 245 mm Torque Converter- 0.766-1.756 mm (0.030-0.069 in) 298 mm/300 mm Torque Converter- 0.866-1.876 mm (0.034-0.074 in)
2. Select the proper forward clutch selective backing plate (650) to obtain the correct travel. Refer to «Forward Clutch Backing Plate Selection»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__forward-clutch-backing-plate-selection) .

3-4 Clutch Assemble

1. Inspect the 3rd and 4th clutch apply plate (653), the fiber plate assemblies (654A), the steel plates (654B) and the selective backing plate (655) for the following conditions: Damaged tangs Delamination Excessive wear Heat damage or wear Surface finish Flatness
2. Install the 3rd and 4th clutch apply plate (653) into the input housing. Index each leg of the apply plate into the apply ring legs.
3. Install the 3rd and 4th clutch plates starting with a fiber plate assembly (654A) and alternate with a steel plate (654B).
4. Continue the stack up if seven 654A plates are used.
5. Inspect the five 3-4 clutch boost spring assemblies (600) for damaged, worn, broken or missing springs. Springs must be held securely by retainer.
6. Install the 3-4 clutch boost spring assemblies (600) into the input housing.
7. Install the 3rd and 4th clutch selective backing plate (655). Some models may have a chamfer on one side of the selective backing plate. Install the chamfer side up.
8. Install the 3rd and 4th clutch backing plate retainer ring (656).

3-4 Clutch Plate Travel Check

1. Use feeler gauges to check the 3rd and 4th clutch plate travel.
2. Check the travel between the selective backing plate (655) and the first fiber plate assembly (654A). The 3rd and 4th clutch plate travel should be 0.90-2.10 mm (0.035-0.083 in).
3. Select the proper 3rd and 4th clutch selective backing plate to obtain the correct travel. Refer to «Third and Fourth Clutch Backing Plate Selection»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__third-and-fourth-clutch-backing-plate) .

Inspection Procedure

Scheme 28

Apply air into the feed holes in the turbine shaft in order to check the following items

1. The 3rd and 4th clutch (1)
2. The forward clutch (2)
3. The overrun clutch (3)

Turbine Shaft Seals Installation

Tools Required

1. J 36418-1B Turbine Shaft Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 36418-2A Turbine Shaft Seal Sizer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Use the J 36418-1B in order to install the four turbine shaft oil seal rings (619).
2. Place the J 36418-2A over the turbine shaft oil seal rings (619). Leave the J 36418-2A on the shaft until the reverse input clutch must be installed on the input clutch.

Reverse Input Clutch Disassemble

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Remove the reverse input clutch retaining ring (614).
2. Remove all reverse input clutch plates (611-613).
3. Install the J 23327-1 and the J 25018-A .
4. Compress the reverse input clutch spring assembly.
5. Remove the reverse input clutch spring retainer ring (610).
6. Remove the reverse input clutch spring assembly (609).
7. Remove the reverse input clutch piston assembly (607).

Tools Required

1. J 25019 Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 7004-A Universal Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 8092 Universal Driver Handle - 3/4 in - 10

1. Inspect the reverse input clutch housing and drum assembly for the following conditions: Damaged or worn bushings Surface finish on the hub and outer housing - check band surface for flatness Leak at the weld Heat distortion Rolled or distorted retaining ring groove
2. Using the J 25019-16 with the J 7004-A , remove the reverse input clutch front bushing (603).
3. Using the J 25019-4 with the J 8092 , remove the reverse input clutch rear bushing (606).

1. Using the J 25019-9 with the J 8092 , install a reverse input clutch front bushing (603).
2. Using the J 34196-3 which is part of kit J 34196-B with the J 8092 , install a reverse input clutch rear bushing (606).

Reverse Input Clutch Assemble

Tools Required

1. J 23327-1 Forward Clutch Spring Compressor (Bridge). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 25018-A Clutch Spring Compressor Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 44571-1 Reverse Input Clutch Piston Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the reverse input clutch piston (607) for the following defects: Damaged or porosity Ring groove damage
2. Install the reverse input clutch inner and outer seals (608) on the piston.
3. Install the J 44571-1 inner (2) and outer (1) reverse input clutch piston installer.
4. Install the piston (607 into the housing (605).
5. Remove the J 44571-1 .
6. Inspect the reverse input clutch spring assembly (609) for distortion or damage.
7. Install the reverse input clutch spring assembly (609).
8. Install the J 23327-1 and the J 25018-A .
9. Install the reverse input clutch spring retainer ring (610).
10. Inspect the belleville plate (611), the fiber plate assemblies (612B), the steel turbulator plates (612A) and the selective backing plate (613) for the following items: Damaged tangs Delamination Excessive wear Heat damage or wear Surface finish Flatness
11. Install the reverse input clutch belleville plate (611), with the inner diameter up, into the reverse input clutch housing and drum assembly (605).
12. Install the reverse input clutch plates starting with a steel turbulator plate (612A) and alternate with a fiber plate assembly (612B).
13. Install the reverse input clutch selective backing plate (613).
14. Install the reverse input clutch retaining ring (614).

Reverse Input Clutch Plate Travel Check

1. Apply an evenly distributed load to the clutch pack.
2. Use feeler gages to check the reverse input clutch plate travel.
3. Check the travel between the selective backing plate and the reverse input clutch retainer ring. Clutch Plate Travel Specifications: The reverse input clutch plate travel should be 1.02-1.94 mm (0.040-0.076 in).
4. Select the proper selective backing plate to obtain the correct travel. Refer to «Reverse Input Clutch Backing Plate Selection»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__reverse-input-clutch-backing-plate-selection) .

Reverse Input and Input Clutches Installation

1. Install the selective thrust washer (616) on the input housing (621).
2. Install the stator shaft/selective washer bearing assembly (615) on the input housing (621). The black race on the bearing goes toward the oil pump.
3. Install the reverse input clutch assembly (605) on the input housing (621).
4. Index the reverse input clutch plates with the input clutch hub. Make certain all clutch plates are fully engaged.
5. Install the reverse input and the input clutch assembly into the transmission case.
6. Index the 3rd and 4th clutch plates with the input internal gear. Ensure that all clutch plates are fully engaged. When properly assembled, the reverse input clutch housing will be located just below the case oil pump face.

2-4 Band Assembly Installation

1. Inspect the 2-4 band assembly (602) for damage or wear.
2. Install the 2-4 band (602) into the case.
3. Install the band anchor pin into the case.
4. Index the band to fit the band anchor pin into the band.

Oil Pump Disassemble

1. Remove the thrust (pump to drum) washer (601).
2. Remove the oil (pump to case) O-ring seal (5) - some models.
3. Remove the pump cover bolts (233).
4. Remove the pump cover (215) from the pump body (200).

Oil Pump Body Disassemble

1. Remove the pump slide inner (207) and outer (206) springs or spring (245) - some models.
2. Place a rag over the spring or springs while removing them to prevent the springs from flying out.
3. Remove the oil pump rotor (212) and pump vane rings (210).
4. Remove the pump vanes (213).
5. Remove the rotor guide (211).
6. Remove the pump slide (203), pump slide support seal (208) and the pump slide seal (209).
7. Remove the slide seal back-up O-ring seal (202) and the oil seal - slide to wear plate, ring (201).
8. Remove the pivot slide pin (205) and the pivot pin spring (204).

1. Refer to «Oil Pump Rotor and Slide Measurement»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__oil-pump-rotor-and-slide-measurement) .
2. Measure the oil pump rotor (212) thickness.
3. Measure the oil pump slide (203) thickness.

Tools Required

1. J 41778-1 Pump Body Bushing Installer/Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 41778-2 Pump Body Bushing Position Stop. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the oil pump body for the following defects: Worn or damaged bushings Foreign material or debris Porosity Scored or irregular mating faces Cross channel leaks Ring groove damage
2. Remove the front helix retainer (244).
3. Remove the oil seal assembly (243).
4. Using the J 41778-1 with an arbor press, remove the pump body bushing (242).
5. Using J 41778-1 with an arbor press, install a new pump body bushing (242).
6. Use the J 41778-2 to ensure proper bushing depth.

Oil Pump Body Assemble

Tools Required

1. J 25016 Pump Seal and speedometer gear Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 36850 Transjel Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Using the J 25016 , install the oil seal assembly (243).
2. Install the front helix retainer (244).
3. Install an O-ring seal (202) and oil seal ring (201) into the groove on the back side of the pump slide (203).
4. Use J 36850 , or an equivalent, to retain the seal and the ring on the slide.
5. Install the pivot pin spring (204) and the pivot pin (205).
6. Install the pump slide (203).
7. Index the slide notch with the pivot pin (205). The oil seal ring must face downward into the pump pocket.
8. Install the pump slide seal support (208) and the pump slide seal (209).
9. Install the pump slide inner (207) and outer (206) springs, some models will use only one fluid pump slide outer spring (245).
10. Install the bottom pump vane ring (210) and the rotor guide (211) into the rotor (212) and retain with J 36850 or an equivalent.
11. Install the rotor (212) with the rotor guide (211) toward the pump pocket.
12. Install the pump vanes (213).
13. Install the top pump vane ring (210).

Oil Pump Cover Disassemble

1. Remove the oil pump reverse boost valve retaining ring (221).
2. Remove the reverse boost valve sleeve (220) and the reverse boost valve (219).
3. Remove the pressure regulator isolator spring (218) and the pressure regulator valve spring (217).
4. Remove the pressure regulator valve (216).
5. Remove the oil pump converter clutch valve retaining ring (222).
6. Remove the stop valve (223) and the converter clutch valve (224).
7. Remove the converter clutch valve inner (225) and outer (226) springs.
8. Remove the pressure relief bolt rivet (227).
9. Remove the pressure relief spring (229) and the pressure relief ball (228).
10. Remove the oil pump cover screen (232) and the oil pump cover screen seal (231).
11. Remove the stator shaft oil seal rings (230).

Tools Required

1. J 7004-A Universal Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 8092 Universal Driver Handle - 3/4 in - 10
3. J 21465-01 Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 34196-B Transmission Bushing Service Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the pump cover, all check valve retainer and ball assemblies (237), cup plugs (235, 236) and orificed cup plugs (238, 240).
2. Inspect the pump cover for the following: Worn or damaged bushings Foreign material or debris Porosity Scored or irregular mating faces Cross channel leaks Ring groove damage
3. Using the J 21465-15 with the J 7004-A , remove the stator shaft front bushing (234).
4. Using the J 25019-14 with the J 7004-A , remove the stator shaft rear bushing (241).

1. Using the J 21465-2 and the J 8092 , install a new stator shaft front bushing (234).
2. Using the J 34196-2 which is part of kit J 34196-B and the J 8092 , install the stator shaft rear bushing (241).

Oil Pump Cover Assemble

Tools Required

1. J 38735-3 Pusher. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 39855 Stator Shaft Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Using the J 39855-1 which is part of kit J 39855 and the J 38735-3 , install the stator shaft oil seal rings (230).
2. Place J 39855-2 which is part of kit J 39855 over the seals.
3. Leave J 39855-2 which is part of kit J 39855 on the stator shaft until just before the pump is to be installed into the transmission.
4. Install the pressure relief ball (228) and pressure relief spring (229).
5. Install the pressure relief bolt rivet (227).
6. Install the oil pump cover screen seal (231) on the (232).
7. Install the oil pump cover screen (232) into the pump cover.
8. Install the converter clutch valve inner (225) and outer (226) springs.
9. Install the converter clutch valve (224).
10. Install the stop valve (223) and the oil pump converter clutch valve retaining ring (222).
11. Install the pressure regulator valve (216).
12. Install the pressure regulator isolator spring (218) and the pressure regulator valve spring (217).
13. Install the reverse boost valve (219) in the reverse boost valve sleeve (220).
14. Install the reverse boost valve and sleeve in the pump cover.
15. Install the oil pump reverse boost valve retaining ring (221).

J 21368 Pump Body and Cover Alignment Band. See Special Tools and Equipment .

Assembly Procedure

1. Place the oil pump cover onto the oil pump body and put stator shaft through a hole in the bench.
2. Install the pump cover bolts (223) finger tight only.
3. Install the J 21368 .
4. Tighten the pump cover bolts (223). Tighten: Tighten the bolts to 24 N.m (18 lb ft).
5. Remove the J 21368 .

Oil Pump Assembly Installation

Tools Required

1. J 25025-1 Dial Indicator Mounting Post. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 39855 Stator Shaft Seal Installer. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install the J 25025-1 .
2. Remove the J 39855-2 which is part of kit J 39855 .
3. Install the pump to drum thrust washer (601).
4. Use J 36850 or equivalent to retain the washer to the pump.
5. Install the oil pump o-ring seal into the oil pump o-ring groove - some models.
6. Install the pump cover to case gasket (6).
7. Install the oil pump assembly (4) into the case and align all holes properly.
8. Install the pump to case bolts (2) with new O-ring seals (3). Tighten: Tighten the bolts to 29 N.m (21 lb ft).
9. Remove the J 25025-1 .
10. Install the remaining pump to case bolts (2) and O-ring seals (3), in the holes where the J 25025-1 were. Tighten: Tighten the bolts to 29 N.m (21 lb ft).

Tools Required

1. J 25022 End Play Fixture Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 34725 End Play Checking Adapter. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 43205 End Play Fixture Adapter (300 mm). See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 24773-A Oil Pump Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
5. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
6. J 25025-7A Dial Indicator Post. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Install an end play fixture adapter. Use J 25022 for a 245 mm and 258 mm turbine shaft (1). Use J 34725 for a 298 mm turbine shaft (2). Use J 43205 for a 300 mm turbine shaft (3).
2. Install the J 24773-A .
3. Remove an oil pump bolt.
4. Install J 25025-7A (or a 278 mm or 11 in bolt) and lock nut.
5. Install J 8001 .
6. Set the J 8001 to zero.
7. Pull up on J 24773-A . Proper end play should be 0.13-0.92 mm (0.005-0.036 in).
8. The selective washer (616), which controls the end play, is located between the input housing (621) and the thrust bearing (615) on the oil pump hub. If the end play measurement is incorrect, refer to the «End Play Specifications»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__end-play-specifications) table. Choose a new selective washer (616) based on the original selective washer and the information contained in the table. If the dial indicator shows no end play, the selective washer (616) and thrust bearing (615) may have been misassembled.
9. Correct the end play by changing the selective washer (616).

J 41510 T-50 Plus Bit. See Special Tools and Equipment .

1. Install the oil pump seal (5) - some models. Seat oil pump seal (5) by hand, between pump body and case. Ensure the seal is evenly seated.
2. Install the converter housing (102).
3. Install the converter housing bolts (94) to the transmission case. Use the J 41510 . Tighten: Tighten converter housing bolts evenly in a star pattern sequence. Tighten the converter housing bolts (94) to 65-75 N.m (48-55 lb ft).

Turbine Shaft O-Ring Installation

Install the O-ring (618) on the turbine shaft. O-Ring location is location dependent.

Control Valve Body Disassemble

1. Remove the manual valve (340).
2. Remove the forward accumulator cover bolts (364) and the forward accumulator cover (363).
3. Remove the forward accumulator spring (356), forward accumulator piston (354), and the forward accumulator pin (355).
4. Remove the low overrun valve spring (362) and the low overrun valve (361).
5. Remove the coiled spring pin (360) and the bore plug (359).
6. Remove the forward abuse valve spring (358) and the forward abuse valve (357).
7. Remove the solenoid retainer (395) and the 1-2 shift solenoid (367A).
8. Remove the 1-2 shift valve (366) and the 1-2 shift valve spring (365).
9. Remove the solenoid retainer (395) and the 2-3 shift solenoid (367B).
10. Remove the 2-3 shuttle valve (369) and the 2-3 shift valve (368).
11. Remove the coiled spring pin (360).
12. Remove the 1-2 accumulator valve sleeve (372).
13. Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370).
14. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). Remove the pressure control solenoid (377), note orientation upon removal.
15. Compress the actuator feed limit valve spring (375).
16. Remove the bore plug retainer (395) and release the spring slowly.
17. Remove the bore plug (376).
18. Remove the actuator feed limit valve spring (375) and the actuator feed limit valve (374).
19. Remove the solenoid retainer (395) and the 3-2 control solenoid (394).
20. Remove the 3-2 control valve (391) and the 3-2 control valve spring (392).
21. Remove the bore plug retainer (395) and the bore plug (381).
22. Remove the 3-2 downshift valve spring (390) and the 3-2 downshift valve (389).
23. Remove the coiled spring pin (360) and the bore plug (359).
24. Remove the reverse abuse valve spring (388) and the reverse abuse valve (387).
25. Remove the bore plug retainer (395) and the bore plug (381).
26. Remove the 3-4 shift valve spring (386) and the 3-4 shift valve (385).
27. Remove the bore plug retainer (395) and the bore plug (381).
28. Remove the regulator apply valve (380) and the regulator apply spring (397) and the isolator valve (398).
29. Remove the bore plug retainer (395) and the bore plug (381).
30. Remove the 3-4 relay valve (384) and the 4-3 sequence valve (383) and the 4-3 sequence valve spring (382).

1. Inspect the valve body to spacer plate gasket for valve body channel witness marks. The witness marks should be complete. Incomplete witness marks may be caused by an uneven case surface. Incomplete witness marks may also be caused by cross-channel leaks.
2. Inspect the valve body casting for the following conditions: Porosity Cracks Damaged machined surfaces Chips or debris

Cleaning Procedure

1. Clean all the valves, springs, bushings, and the control valve body in clean solvent.
2. Dry all the parts using compressed air.

1. Install the following items: The isolator valve (398) The regulator apply spring (397) The regulator apply valve (380) The bore plug (381) The bore plug retainer (395)
2. Install the following items: The 4-3 sequence valve spring (382) The 4-3 sequence valve (383) The 3-4 relay valve (384) The bore plug (381) The bore plug retainer (395)
3. Install the following items: The 3-4 shift valve (385) The 3-4 shift valve spring (386) The bore plug (381) The bore plug retainer (395)
4. Install the following items: The reverse abuse valve (387) The reverse abuse valve spring (388) The bore plug (359) The coiled spring pin (360) The 3-2 downshift valve (389) The 3-2 downshift valve spring (390) The bore plug (381) The bore plug retainer (395)
5. Install the following items: The 3-2 control valve spring (392) The 3-2 control valve (391) The 3-2 control solenoid (394) The solenoid retainer (395)
6. Install the following items: The actuator feed limit valve (374) The actuator feed limit valve spring (375) The bore plug (376) The bore plug retainer (395) The pressure control solenoid (377) 1 - Colorado/Canyon 2 - All other models The solenoid retainer (378) NOTE: Refer to Fastener Notice in Cautions and Notices. The solenoid retainer bolt (364) Tighten: Tighten the bolt to 8-14 N.m (6-10 lb ft).
7. Install the following items: The 1-2 accumulator valve spring (370) The 1-2 accumulator valve (371) in the 1-2 accumulator valve sleeve (372) The 1-2 accumulator valve and sleeve assembly The coiled spring pin (360)
8. Install the following items: The 2-3 shift valve (368) The 2-3 shuttle valve (369) The 2-3 shift solenoid valve (367B) The solenoid retainer (395)
9. Install the following items: The 1-2 shift valve spring (365) The 1-2 shift valve (366) The 1-2 shift solenoid valve (367A) The solenoid valve retainer (395)
10. Install the following items: The forward abuse valve (357) The forward abuse valve spring (358) The bore plug (359) The coiled spring pin (360) The low overrun valve (361) The low overrun valve spring (362)
11. Install the following items: The forward accumulator oil seal (353) on the forward accumulator piston (354) The forward accumulator pin (355) The forward accumulator piston (354) The forward accumulator spring (356) The forward accumulator cover (363) The forward accumulator cover bolts (364)
12. Install the (340).

3-4 Accumulator Installation

1. Inspect the 3-4 accumulator piston (44) for the following conditions: Porosity Cracks Scoring Nicks and scratches
2. Install the 3-4 accumulator piston oil seal ring (45) on the 3-4 accumulator piston (44).
3. Install the 3-4 accumulator piston (44) and seal assembly into the bore.
4. Inspect the 3-4 accumulator spring (46) for cracks.
5. Install the 3-4 accumulator spring.

1-2 Accumulator Disassemble

1. Blow air into the 1-2 accumulator housing (57) to remove the 1-2 accumulator piston (56).
2. Remove the 1-2 inner (104) and outer (54) accumulator springs.

1-2 Accumulator Assemble

1. Inspect the 1-2 accumulator piston (56) for the following conditions: Porosity Cracks Scoring Nicks and Scratches
2. Install a 1-2 accumulator piston oil seal ring (55) on the 1-2 accumulator piston (56).
3. Inspect the 1-2 accumulator housing for the following conditions: Porosity Cracks Scoring Nicks and Scratches Debris or blocked passages
4. Install the 1-2 inner (104) and outer (54) accumulator springs.
5. Install the 1-2 accumulator piston (56).

1-2 Accumulator Installation

Tools Required

1. J 25025-5 Guide Pins. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 36850 Transjel Lubricant. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the valve body spacer plate and the solenoid screens (49, 50) for damage or debris. Replace the solenoid screens (49, 50) if necessary.
2. Install the #1 checkball into the case.
3. Install the J 25025-5 into the case.
4. Place the spacer plate to case gasket (47) (identified by a "C") and the spacer plate to valve body gasket (52) (identified by a "V") on the spacer plate (48). Retain gaskets on the spacer plate with J 36850 or equivalent.
5. Place the spacer and the spacer plate gaskets on the case.
6. Install the spacer plate support plate (53 or 113).
7. Install the spacer plate support bolts (77).
8. Install the accumulator bolt (115), model dependent. Tighten: Tighten the accumulator bolt to 11 N.m (8.11 lb ft).
9. Install the 1-2 accumulator housing assembly (57 or 116).
10. Install the 1-2 accumulator housing bolts (58, 59 or 117, 118). Tighten: Tighten the bolts 58 and 59 to 11 N.m (8 lb ft). Tighten the bolts 117 and 118 to 8-14 N.m (6-10 lb ft).

Control Valve Body Installation

Tools Required

1. J 25025-5 Guide Pins
2. J 36850 Transjel Lubricant

1. Inspect the wiring harness and solenoid assembly for the following conditions: Damage Cracked connectors Exposed wires Loose electrical terminals Damaged wiring loom Worn, missing, or cut pass-through connector O-ring seal.
2. Install the transmission wiring harness pass-through connector into the transmission case. Ensure connector tabs lock into place.
3. Move the harness to one side in order to install the valve body.
4. Install the checkballs (2-6, 8, 12) in the valve body and retain checkballs with J 36850 or an equivalent. Some models do not use a #5 checkball.
5. Install the valve body over the J 25025-5 Guide Pins, and connect the manual valve link to the manual valve.
6. Install two bolts to hold the valve body in place.
7. Remove the J 25025-5 .
8. Install the fluid level indicator stop bracket (93) if equipped and the valve body bolts (62) that are shown only.
9. Finger tighten the bolts.
10. Inspect the Transmission Fluid Pressure (TFP) Manual Valve Position Switch Assembly for the following conditions: Damage Debris Damaged or missing O-rings Cracked connector Loose electrical terminals Poor terminal retention Sediment in switch membrane
11. Install the TFP manual valve position switch (69) and bolts (62, 70).
12. Install the transmission wiring harness on the valve body.
13. Install the TCC solenoid valve and bolts (68). Tighten: Tighten the bolts to 8-14 N.m (6-10 lb ft).
14. Check that all the valve body bolts are in the correct location. Each bolt number refers to a specific bolt size, as indicated by the following list: 1 - M6 x 1.0 x 65.0 2 - M6 x 1.0 x 54.4 3 - M6 x 1.0 x 47.5 4 - M6 x 1.0 x 17.7 5 - M6 x 1.0 x 35.0
15. Tighten the bolts from the center of the valve body working your way out in a spiral pattern to the outside edge. Tighten: Tighten the bolts to 8-14 N.m (6-10 lb ft).
16. Install the TCC PWM solenoid valve (396) and the solenoid retainer (395).
17. Snap the wiring harness in place on the valve body bolts. Ensure the harness loom tab is located under the TFP switch.
18. Install the wiring connectors to the electrical components as indicated by the following list: 1 - Transmission Fluid Pressure (TFP) manual valve position switch 2 - 1-2 Shift Solenoid 3 - 2-3 Shift Solenoid 4 - Pressure Control Solenoid (PCS) 5 - Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid 6 - 3-2 Shift Solenoid

Manual Detent Spring Installation

1. Inspect the manual detent spring assembly (63) for cracks or damage.
2. Install the manual detent spring assembly (63).
3. Install the manual detent spring bolt (64). Tighten: Tighten the bolt to 20-27 N.m (15-20 lb ft).

J 41510 T-50 Plus Bit. See Special Tools and Equipment .

1. Install the secondary fluid pump to the valve body.
2. Install the secondary fluid pump bolts (109, 110). Tighten: Tighten the secondary fluid pump bolts to 11-14 N.m (8-10 lb ft).
3. Connect the electrical connector to the secondary fluid oil pump.

Oil Filter Assembly Installation

1. Lubricate the filter seal (71) with transmission fluid.
2. Use a socket the same size diameter as the filter seal (71) and install the seal.
3. Install the transmission oil filter assembly (72).

Secondary Fluid Pump Filter Replacement (M33 Model Only)

1. Remove the secondary fluid pump. Refer to «Secondary Fluid Pump Assembly Removal (M33 Model Only)»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul__secondary-fluid-pump-assembly-removal-m33) .
2. Remove the retaining push clip from the secondary fluid pump.
3. Rotate filter upward and separate from the pump.
4. Install a new filter and rotate filter downward.
5. Install a new push clip.
6. Install the secondary fluid pump. Refer to «Secondary Fluid Pump Assembly Installation (M33 Model Only)»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

Transmission Oil Pan Installation

1. Place the transmission oil pan gasket (73) on the case.
2. Place the transmission oil pan (75) on the case.
3. Install all of the transmission oil pan screws (76). Tighten: Tighten the screws to 16 N.m (11.8 lb ft).

J 22269-01 Accumulator and Servo Piston Remover. See Special Tools and Equipment .

Disassembly Procedure

1. Use a J 22269-01 to compress the second apply piston assembly (17).
2. Remove the second apply piston retaining ring (14).
3. Remove the servo cushion spring retainer (15), the servo cushion outer spring (16) and the servo cushion inner spring (105) (model dependent).

J 33037 2-4 Intermediate Band Apply Pin Gage. See Special Tools and Equipment .

1. Install the band apply pin and the J 33037 .
2. Install the servo cover retaining ring to secure the tool.
3. Apply 11 N.m (98 lb in) torque. If the white line appears in the gage slot (1), the pin length is correct.
4. If a new pin is needed, refer to «2-4 Servo Pin Selection»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) in order to determine the correct pin length.

2-4 Servo Assembly Installation

Tools Required

1. J 22269-01 Accumulator and Servo Piston Remover. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 29714-A Servo Cover Depressor. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the 4th apply piston (25), the 2-4 servo cover (28), the 2nd apply piston (17), and the servo piston inner housing (20) for the following conditions: Cracks Scoring Burrs and nicks
2. Install the following seals: The 4th apply piston outer oil seal ring (26) on the 4th apply piston (25). The 2-4 servo cover O-ring seal (27) on the 2-4 servo cover (28). The 2nd apply piston outer (18) and inner (19) oil seal rings on the 2nd apply piston (17). The O-ring seal (21) on the servo piston inner housing (20).
3. Install the servo cushion outer spring (16), the servo cushion inner spring (105) (model dependent) and the cushion spring retainer (15) in the 2nd apply piston (17).
4. Use the J 22269-01 and compress the second apply piston assembly (17).
5. Install the second apply piston retaining ring (14).
6. Assemble the 2-4 servo components in the order shown: (12-15, 17, 20, 22-25, 28, 29).
7. Install the 2-4 servo assembly into the 2-4 servo bore.
8. Install the J 29714-A .
9. Tighten the bolt on the J 29714-A in order to compress the servo cover.
10. Install the servo cover retaining ring.

Case Extension Bushing Replacement (2WD Truck/Utility/Van Only )

Tools Required

1. J 8092 Driver Handle
2. J 23062-14 Bushing Remover
3. J 34196-B Transmission Bushing Service Set

1. Inspect the case extension for the following conditions: Porosity Cracks Nicks Burrs Worn bushings
2. Remove the case extension oil seal assembly (34) (model dependent).
3. Using the J 23062-14 and the J 8092 , remove the case extension bushing (33).
4. Using the J 34196-4 which is part of kit J 34196-B and the J 8092 , install a case extension bushing (33).

J 21426 Rear Seal Installer. See Special Tools and Equipment .

1. Using the J 21426 , install an output shaft sleeve (690) and an output shaft seal (691). Do not push the sleeve past the machined surface on the output shaft.
2. Install the case extension to case seal (30) and the case extension (31).
3. Install the case extension to case bolts (32). Tighten: Tighten the bolts to 45 N.m (33 lb ft).
4. Inspect the transmission speed sensor for the following conditions: Cracks Nicks Damage
5. Install a new O-ring seal (37) on the internal transmission speed sensor (36).
6. Install the internal transmission speed sensor (36).
7. Install the speed sensor retaining bolt (35). Tighten: Tighten the bolt to 12 N.m (9 lb ft).
8. Using the J 21426 , install the case extension oil seal assembly (34) (model dependent).

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
2. J 26900-13 Magnetic Indicator Base. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
3. J 35138 Converter End Play Checker. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .
4. J 39195 Converter End Play Check Tool. See «Special Tools and Equipment»(/chevrolet/chevy-express-g3500/1996-2012/remont/automatic-trans/#automatic-transmission-4l60-e4l65-e-overhaul) .

1. Inspect the torque converter and replace if any of the following conditions exist: Evidence of damage to the pump assembly. Metal particles are found after flushing the cooler and cooler lines. External leaks in the hub area. Converter pilot is broken, damaged or poor fit into the crankshaft. Converter hub is scored or damaged. Internal damage to the stator. Contamination from engine coolant. Excessive end play.
2. Install the J 35138 , the J 26900-13 and the J 8001 or J 39195 to be used with the 300 mm torque converter. Specification: The end play for a 245 mm torque converter should be 0-0.38 mm (0-0.015 in). The end play for a 298 mm torque converter should be 0.1-0.48 mm (0.004-0.019 in). The end play for a 258 mm and 300 mm torque converter should be 0.1-0.5 mm (0.004-0.020 in).
3. Remove the tools.

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

1. Install the torque converter.
2. Install the J 21366 .

J 8763-B Holding Fixture and Base. See Special Tools and Equipment .

Scheme 29

Remove the transmission from the J 8763-B .

Scheme 30

Park - Engine Running

With the gear selector lever in the PARK (P) position and the engine running, the line pressure from the oil pump assembly is directed to various components in the valve body and the oil pump.

Pressure Regulator Valve

The pressure regulator valve regulates the oil pump output (line pressure) in response to the signal fluid pressure, the spring force and the line pressure acting on the end of the valve. The line pressure is routed through the valve and into both the converter feed and the decrease fluid circuits. Regulated line pressure is also directed to the manual valve, the converter clutch valve, the actuator feed limit valve, and the regulated apply valve.

Pressure Relief Valve

Controlled by spring force, this checkball limits the maximum value of the line pressure. When the line pressure reaches this limiting value, fluid is exhausted past the ball and returns to the sump.

Line Pressure Tap

The line pressure tap provides a location to measure the line pressure with a fluid pressure gage.

Actuator Feed Limit Valve

Biased by spring force and orificed AFL fluid, it limits the maximum value of line pressure entering the AFL fluid circuit. Below this limiting value, the AFL fluid pressure equals the line pressure. The AFL fluid is routed to the pressure control solenoid valve, the 3-2 control solenoid valve, the TCC PWM solenoid valve, the 1-2 and 2-3 shift solenoid valves, and the 2-3 shift valve train.

Pressure Control (PC) Solenoid Valve

Controlled by the powertrain control module (PCM), the PC solenoid valve regulates the filtered AFL fluid into the torque signal fluid pressure. The PCM controls this regulation by varying the current value to the PC solenoid valve in relation to the throttle position and other vehicle operating conditions.

Torque Converter Clutch PWM Solenoid and Regulator Apply and Isolator Valve

AFL fluid is routed to the TCC PWM solenoid valve, in Park the PCM has the duty cycle turned OFF. This prevents AFL fluid from entering the converter clutch signal fluid circuit. Regulated line pressure is routed to the regulator apply valve, which is open with CC signal circuit empty, and blocks line pressure from entering the regulated apply circuit. Any fluid in the regulated apply circuit will exhaust at the regulated apply valve.

TCC Solenoid Valve

Under normal operating conditions, the PCM keeps the normally open TCC solenoid valve de-energized (OFF). Converter feed fluid exhausts through the open TCC solenoid valve, and spring force keeps the converter clutch apply valve in the release position.

Converter Clutch Valve

Held in the release position by spring force, it directs converter feed fluid into the release fluid circuit. Also, fluid returning from the converter in the apply fluid circuit is routed through the valve and into the cooler fluid circuit.

Torque Converter

Release fluid pressure unseats the TCC apply checkball (#9), keeps the pressure plate released from the converter cover and fills the converter with fluid. Fluid exits the converter between the converter hub and the stator shaft in the apply fluid circuit.

Cooler and Lubrication System

Cooler fluid from the converter clutch apply valve is routed through the transmission fluid cooler and into the lubrication fluid circuits.

Manual Valve

Controlled by the selector lever and the manual shaft, the manual valve is in the Park (P) position and directs the line pressure into the PR (Park/Reverse) fluid circuit. Line pressure is blocked from entering any other fluid circuit at the manual valve.

Lo and Reverse Clutch Piston

The PR fluid seats the lo and reverse clutch checkball (#10) and is orificed to the outer area of the piston. Orificing the PR fluid around the #10 checkball helps control the lo and reverse clutch apply. Also, Lo/reverse fluid pressure from the lo overrun valve acts on the inner area of the lo and reverse clutch piston in order to increase the clutch holding capacity.

Lo Overrun Valve

The PR fluid pressure moves the valve against the spring force and fills the Lo/reverse fluid circuit. Lo/reverse fluid is orificed (323) back to the lo overrun valve in order to assist the PR fluid in moving the valve against the spring force. The spring force provides a time delay for the PR fluid filling the Lo/reverse fluid circuit. The Lo/reverse fluid is routed to the inner area of the lo and reverse clutch piston in order to increase the holding capacity of the clutch.

Transmission Fluid Pressure (TFP) Manual Valve Position Switch Assembly

The TFP manual valve position switch consists of five fluid pressure switches: D2 and D3 are normally closed and D4, Lo and Rev are normally open. All fluid circuits routed to the assembly are empty and the TFP manual valve position switch signals the PCM that the transmission is in either Park or Neutral.

Shift Solenoid Valves (1-2 and 2-3)

Both shift solenoid valves, which are normally open, are energized by the PCM and block fluid from exhausting. This maintains the signal A fluid pressure at the 1-2 shift solenoid valve and signal B fluid pressure at the 2-3 shift solenoid valve.

Shift Valves (1-2, 2-3 and 3-4)

Signal A fluid pressure holds the 1-2 shift valve in the downshift position and the 3-4 valve in the upshift (first and fourth gear) position. The signal B fluid pressure from the 2-3 shift solenoid valve holds the 2-3 shift valve train in the downshift position.

Scheme 31

Reverse

When the gear selector lever is moved to the Reverse (R) position (from the Park position), the following changes occur to the transmissions hydraulic and electrical systems

The manual valve moves to the Reverse position and line pressure enters the reverse fluid circuit. As in Park, line pressure also fills the PR (Park/Reverse) fluid circuit. All other fluid circuits are blocked by the manual valve.

Lo and Reverse Clutch

As in Park, PR fluid pressure acts on the outer area of the lo and reverse clutch piston to apply the lo and reverse clutch. Also, Lo/reverse fluid from the lo overrun valve acts on the inner area of the piston to increase the holding capacity of the clutch (see Note below).

Reverse Input Checkball (#3)

Reverse fluid pressure seats the #3 checkball, flows through orifice #17 and fills the reverse input fluid circuit. This orifice helps control the reverse input clutch apply rate when engine speed is at idle.

Reverse Abuse Valve

Reverse fluid pressure acts on the end of the valve opposite of spring force. At engine speeds above idle, reverse fluid pressure, which is fed by line pressure, increases and moves the valve against spring force (as shown). Reverse fluid can then fill the reverse input fluid circuit through the reverse abuse valve. This bypasses the control of orifice #17 and provides a faster clutch apply.

Boost Valve

Reverse input fluid pressure moves the boost valve against the pressure regulator valve spring. The spring acts on the pressure regulator valve to increase the operating range of line pressure in Reverse. Reverse input fluid also flows through the valve and to the reverse input clutch piston. Remember that torque signal fluid pressure continually acts on the boost valve to control line pressure in response to vehicle operating conditions.

Reverse Input Clutch Piston

Reverse input fluid pressure moves the piston to apply the reverse input clutch plates and obtain Reverse.

Reverse Input Air Bleed Checkball

This ball and capsule is located in the reverse input fluid circuit in the oil pump to provide an air escape when the fluid pressure increases. It also allows air into the circuit to displace the fluid when the clutch releases.

Reverse input fluid pressure closes the normally open reverse switch in the TFP manual valve position switch This signals the PCM that the manual valve is in the Reverse (R) position.

Both shift solenoid valves are energized as in the Park range. Signal A and signal B fluids are blocked from exhausting through the shift solenoid valves to maintain fluid pressure in these circuits at the end of the shift valves.

Signal A fluid pressure holds the 1-2 shift valve in the downshifted position and the 3-4 shift valve in the upshifted (First and Fourth gear) position. Signal B fluid pressure from the 2-3 shift solenoid valve holds the 2-3 shift valve train in the downshifted position.

The PC solenoid valve continues to regulate AFL fluid into torque signal fluid pressure. The PCM varies the current at the solenoid to regulate torque signal fluid pressure in response to throttle position and other PCM input signals. Torque signal fluid pressure is used to control line pressure at the boost and pressure regulator valves.

Note: The explanation in each gear range is, for the most part, limited.

Scheme 32

Neutral - Engine Running

When the gear selector lever is moved to the Neutral position (N) from the Reverse position, the following changes occur to the transmission hydraulic and electrical systems.

In the Neutral position, the manual valve blocks the line pressure from entering any other fluid circuits. Reverse and PR fluids exhaust past the manual valve.

PR and Lo/reverse fluids exhaust from the piston, thereby releasing the lo and reverse clutch plates. Exhausting PR fluid unseats the lo and reverse clutch checkball (#10) for a quick exhaust.

Spring force closes the valve when the PR fluid pressure exhausts. Lo/reverse fluid exhausts through the valve, into the Lo/1st fluid circuit, past the 1-2 shift valve, into the Lo fluid circuit and through an exhaust port at the manual valve.

Reverse input fluid pressure exhausts from the piston, through the boost valve, past the #3 checkball and to the manual valve. With the reverse input fluid exhausted, the reverse input clutch plates are released and the transmission is in Neutral.

Reverse fluid pressure exhausts and spring force closes the valve.

Reverse input fluid pressure exhausts and line pressure returns to the normal operating range as in the Park and Overdrive positions.

Exhausting reverse input fluid unseats the ball for a quick exhaust through the reverse fluid circuit and past the manual valve.

Reverse input fluid exhausts from the TFP manual valve position switch. With no other fluid routed to it, the TFP manual valve position switch signals the PCM that the transmission is operating in either Park or Neutral.

Scheme 33

Overdrive Range, First Gear

When the gear selector lever is moved to the Overdrive position, from the neutral position, the following changes occur to the transmission's hydraulic and electrical systems

Line pressure flows through the manual valve and fills the D4 fluid circuit. All other fluid circuits remain empty with the manual valve in the Overdrive position.

Forward Clutch Accumulator Checkball (#12)

D4 fluid pressure seats the checkball and is orificed (#22) into the forward clutch feed fluid circuit. This orifice helps control the forward clutch apply rate.

Forward Clutch Accumulator Piston

Forward clutch feed fluid pressure moves the piston against spring force. This action absorbs some of the initial increase of forward clutch feed fluid pressure to cushion the forward clutch apply.

Forward Clutch Abuse Valve

D4 fluid pressure acts on the valve opposite of spring force. At engine speeds greater than idle, D4 fluid pressure increases and moves the valve against spring force (as shown). D4 fluid can then quickly fill the forward clutch feed fluid circuit, thereby bypassing the control of orifice #22 and providing a faster apply of the forward clutch. Otherwise, with increased throttle opening and engine torque, the clutch may slip during apply.

D4 fluid pressure is routed to the TFP manual valve position switch and closes the normally open D4 fluid pressure switch. This signals the PCM that the transmission is operating in Overdrive range.

1-2 Shift Solenoid (SS) Valve

Energized (ON) as in Neutral, the normally open solenoid is closed and blocks signal A fluid from exhausting through the solenoid. This maintains pressure in the signal A fluid circuit.

2-3 Shift Solenoid (SS) Valve

Energized (ON) as in Neutral, the normally open solenoid is closed and blocks signal B fluid from exhausting through the solenoid. This maintains signal B fluid pressure at the solenoid end of the 2-3 shift valve.

2-3 Shift Valve Train

Signal B fluid pressure at the solenoid end of the 2-3 shift valve holds the valve train in the downshifted position against AFL fluid pressure acting on the 2-3 shift valve. In this position, the 2-3 shuttle valve blocks AFL fluid from entering the D432 fluid circuit. The D432 fluid circuit is open to an exhaust port past the valve.

1-2 Shift Valve

Signal A fluid pressure holds the valve in the downshifted position against spring force. In the First gear position, the valve blocks D4 fluid from entering the 2nd fluid circuit.

Accumulator Valve

Biased by torque signal fluid pressure, spring force and orificed accumulator fluid pressure at the end of the valve, the accumulator valve regulates D4 fluid into accumulator fluid pressure. Accumulator fluid is routed to both the 1-2 and 3-4 accumulator assemblies in preparation for the 1-2 and 3-4 upshifts respectively.

Rear Lube (All Except Y-Car)

D4 fluid is routed through an orifice cup plug (#24) in the rear of the transmission case to feed the rear lube fluid circuit.

Remember that the PC solenoid valve continually varies torque signal fluid pressure in relation to throttle position and vehicle operating conditions. This provides a precise control of line pressure.

3-2 Control Solenoid Valve

The PCM keeps the solenoid OFF in First gear and the normally closed solenoid blocks filtered AFL fluid from entering the 3-2 signal fluid circuit.

Torque Converter Clutch PWM Solenoid Valve

In first gear, at approximately 6 mph, the PCM operates the TCC PWM solenoid valve at approximately a 90 percent duty cycle. This opens the AFL fluid circuit, to fill the converter clutch signal fluid circuit through the #9 orifice, and flows to the isolator valve. The CC signal fluid pressure, acting on the isolator valve, will move the regulated apply valve towards the closed position. Regulated line pressure is now routed into the regulated apply circuit, and flows to the closed converter clutch valve, and is blocked from entering the converter clutch apply circuit. Regulated apply fluid is routed through the #8 orifice to the front of the regulated apply valve, and regulates the line pressure entering the regulated apply circuit, in response to the CC signal fluid acting on the isolator valve.

Scheme 34

Overdrive Range, Second Gear

As vehicle speed increases and other operating conditions are appropriate, the PCM de-energizes the 1-2 shift solenoid valve in order to shift the transmission to second gear.

De-energized (turned OFF) by the PCM, the normally open solenoid opens and signal A fluid exhausts through the solenoid.

Energized (ON) as in first gear, the 2-3 shift solenoid valve blocks signal B fluid from exhausting through the solenoid. This maintains signal B fluid pressure at the solenoid end of the 2-3 shift valve.

Without signal A fluid pressure, spring force moves the valve into the upshift position. D4 fluid is routed through the valve and fills the 2nd fluid circuit.

1-2 Shift Checkball (#8)

The 2nd fluid pressure seats the #8 checkball, flows through orifice #16, and fills the 2nd clutch fluid circuit. This orifice helps control the 2-4 band apply rate.

2-4 Servo Assembly

The 2nd clutch fluid pressure moves the #8 checkball, flows through orifice #16 and fills the 2nd clutch fluid circuit. This orifice helps to control the 2-4 band apply rate.

1-2 Accumulator

The 2nd clutch fluid pressure also moves the 1-2 accumulator piston against the spring force and the accumulator fluid pressure. This action absorbs the initial 2nd clutch fluid pressure in order to cushion the 2-4 band apply rate. Also, the movement of the 1-2 accumulator piston forces some accumulator fluid out of the accumulator assembly. This accumulator fluid is routed back to the accumulator valve.

The accumulator fluid forced out of the 1-2 accumulator is orificed (#30) to the end of the accumulator valve. This pressure moves the valve against the spring force and the torque signal fluid pressure in order to regulate the exhaust of excess accumulator fluid. This regulation provides additional control for the 2-4 band apply rate. The fluid circuit shows the exhaust of the accumulator fluid during the shift by the arrow directions in the accumulator fluid circuit.

The signal B fluid pressure from the 2-3 shift solenoid valve holds the valve train in the downshift position. The 2nd fluid is routed through the 2-3 shuttle valve and fills the servo feed fluid circuit.

3-4 Relay Valve and 4-3 Sequence Valve

Spring force holds these valves in the downshift position (first, second and third gear positions). The 2nd fluid is blocked by the 3-4 relay valve and the servo feed fluid is blocked by both valves in preparation for a 3-4 upshift.

3-2 Downshift Valve

Spring force holds the valve closed, blocking the 2nd fluid and the 2nd clutch fluid. This valve is used in order to help control the 3-2 downshift.

In second gear, the PCM energizes the normally closed solenoid. This opens the AFL fluid circuit to fill the 3-2 signal fluid circuit.

3-2 Control Valve

The 3-2 signal fluid pressure moves the valve against the spring force. This action does not affect the transmission operation in second gear.

3-4 Shift Valve

Signal A fluid pressure exhausts and spring force moves the valve into the downshift position (second and third gear positions).

Overrun Clutch Applied - M33 Only

In order to achieve the highest fuel efficiency, the overrun clutch is applied during vehicle coast and braking. With the transmission in overdrive and either second or third gear, the overrun clutch is applied, allowing power to be transferred back through the torque converter to the electric machine and engine.

With the transmission in the D4 range and in either third or second gear, the M33 model applies the overrun clutch in order to maximize fuel efficiency during vehicle coast and braking. In this state, vehicle inertia is used to drive the engine and the electrical machine through the transmission. While in D4 third gear, the 2-3 SS valve is de-energized and the 2-3 shift valve train is in the upshift position. However, D3 oil is not available to apply the overrun clutch. In order to apply the overrun clutch, the spacer plate is used to redirect D2 oil to the overrun clutch circuit through the 2-3 valve train.

In D4 second gear, the 2-3 SS valve is energized and the 2-3 shift valve train is in the downshift position normally allowing overrun clutch circuit to exhaust. With the spacer plate redirecting the D2 oil, the overrun clutch can be applied.

Control Valve Body Ball Check Valve - M33 Only

Fluid pressure, from the automatic transmission secondary fluid pump assembly, unseats the ball check valve to allow fluid flow to the manual valve, where it is directed to the overrun clutch hydraulic circuit. The check valve prevents fluid, from the main transmission oil pump, from flowing into the secondary fluid pump.

Under normal operating conditions, in Overdrive Range-Second Gear, the PCM keeps the normally open TCC solenoid valve de-energized. Converter feed fluid exhausts through the open solenoid, and spring force keeps the converter clutch apply valve in the release position.

Scheme 35

Overdrive Range, Third Gear

As vehicle speed increases further and other vehicle operating conditions are appropriate, the PCM de-energizes the normally open 2-3 shift solenoid valve in order to shift the transmission into Third gear.

De-energized (turned OFF) by the PCM, the solenoid opens and actuator feed limit signal B fluid exhausts through the solenoid.

Note: AFL fluid continues to feed signal B fluid to the solenoid through orifice #29. However, the exhaust port through the solenoid is larger than orifice #29 to prevent a buildup of pressure in the signal B fluid circuit at the solenoid end of the 2-3 shift valve. Exhausting signal B fluid is represented by the arrows through the solenoid.

AFL fluid pressure at the 2-3 shift valve moves the valve train toward the solenoid. In the upshifted position, the following changes occur

1. AFL fluid is routed through the 2-3 shift valve and fills the D432 fluid circuit.
2. 2nd fluid is blocked from entering the servo feed fluid circuit and is orificed (#28) into the 3-4 signal fluid circuit. This orifice helps control the 3-4 clutch apply rate.
3. Servo feed fluid exhausts past the valve into the 3-4 accumulator fluid circuit and through an exhaust port at the 3-4 relay valve.

3-4 Clutch Exhaust Checkball (#4)

3-4 signal fluid unseats the ball and enters the 3-4 clutch fluid circuit.

3-4 Clutch Piston

3-4 clutch fluid pressure moves the piston to apply the 3-4 clutch plates and obtain 3rd gear. However, the 2-4 band must release as the 3-4 clutch applies.

3rd Accumulator Checkball (#2)

3-4 clutch fluid pressure unseats the ball and fills the 3rd accumulator fluid circuit.

3rd Accumulator Exhaust Checkball (#7)

3rd accumulator fluid seats the ball against the orificed exhaust and is routed to the released side of the 2nd apply piston. Before the #7 checkball seats, air in the 3rd accumulator fluid circuit is exhausted through the orifice.

3rd accumulator fluid pressure acts on the release side of the 2nd apply piston and assists servo return spring force. The surface area on the release side of the piston is greater than the surface area on the apply side. Therefore, 3rd accumulator fluid pressure and servo return spring force move the 2nd apply piston against 2nd clutch fluid pressure. This action serves two functions

1. Move the apply pin to release the 2-4 band.
2. Act as an accumulator by absorbing initial 3-4 clutch fluid to cushion the 3-4 clutch apply rate. Remember that the 3rd accumulator fluid circuit is fed by 3-4 clutch fluid.

3-4 clutch fluid pressure moves the valve against spring force. This opens the valve and allows 2nd fluid to feed the 2nd clutch fluid circuit through the valve.

3-2 Control Solenoid Valve and 3-2 Control Valve

The solenoid remains open and routes AFL fluid into the 3-2 signal fluid circuit. 3-2 signal fluid pressure holds the 3-2 control valve against spring force, thereby blocking the 3rd accumulator and 3-4 clutch fluid circuits.

1-2 Shift Solenoid (SS) Valve and 1-2 Shift Valve

The 1-2 SS valve remains de-energized and signal A fluid is exhausted through the solenoid. Also, D432 fluid pressure from the 2-3 shift valve assists spring force to hold the 1-2 shift valve in the upshifted position.

Spring force holds the valve in the downshifted position, blocking 3-4 clutch fluid in preparation for a 3-4 upshift.

In order to achieve the highest fuel efficiency, the overrun clutch is applied during vehicle coast and braking. With the transmission in overdrive and either second or third gear, the overrun clutch is applied, allowing power to be transferred back through the torque converter to the electric machine and engine.

With the transmission in the D4 range and in either third or second gear, the M33 model applies the overrun clutch in order to maximize fuel efficiency during vehicle coast and braking. In this state, vehicle inertia is used to drive the engine and the electrical machine through the transmission. While in D4 third gear, the 2-3 SS valve is de-energized and the 2-3 shift valve train is in the upshift position. However, D3 oil is not available to apply the overrun clutch. In order to apply the overrun clutch, the spacer plate is used to redirect D2 oil to the overrun clutch circuit through the 2-3 valve train.

In D4 second gear, the 2-3 SS valve is energized and the 2-3 shift valve train is in the downshift position normally allowing overrun clutch circuit to exhaust. With the spacer plate redirecting the D2 oil, the overrun clutch can be applied.

Fluid pressure, from the automatic transmission secondary fluid pump assembly, unseats the ball check valve to allow fluid flow to the manual valve, where it is directed to the overrun clutch hydraulic circuit. The check valve prevents fluid, from the main transmission oil pump, from flowing into the secondary fluid pump.

Under normal operating conditions, in Overdrive Range-Third Gear, the PCM keeps the normally open TCC solenoid valve de-energized. Converter feed fluid exhausts through the open solenoid, and spring force keeps the converter clutch apply valve in the release position. However, at speeds above approximately 121 km/h (75 mph), with the transmission still in third gear, the PCM will command TCC apply in third gear. Refer to Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied for more information on TCC apply.

Scheme 36

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

At higher vehicle speeds, the Hydra-matic 4L60-E transmission uses an overdrive gear ratio (fourth gear) in order to increase fuel economy and in order to maximize engine performance. When vehicle operating conditions are appropriate, the PCM energizes the 1-2 shift solenoid valve to shift the transmission into fourth gear.

Energized (turned ON) by the PCM, the normally open solenoid closes and blocks signal A fluid from exhausting through the solenoid. This creates pressure in the signal A fluid circuit.

De-energized (OFF) as in third gear, the 2-3 shift solenoid valve exhausts signal B fluid through the solenoid.

D432 fluid pressure from the 2-3 shift valve and spring force hold the valve in the upshift position against signal A fluid pressure.

Signal A fluid pressure moves the valve into the upshift position against the spring force. In this position, the valve routes 3-4 signal fluid into the 4th signal fluid circuit.

4th signal fluid pressure moves both valves into the upshift (fourth gear) position against the spring force acting on the 4-3 sequence valve. This causes the following changes

1. Orificed (#7) 2nd fluid is routed through the 3-4 relay valve and into the servo feed fluid circuit.
2. Servo feed fluid is routed through the 4-3 sequence valve and into the 4th fluid circuit.
3. 3-4 accumulator fluid routed from the 2-3 shuttle valve is blocked by both valves.

4th fluid is routed through the center of the servo apply pin and acts on the apply side of the 4th apply piston. 4th fluid pressure moves the 4th apply piston against the apply pin spring force acting on the release side of the 4th apply piston. This action moves the apply pin and applies the 2-4 band in order to obtain fourth gear.

The valve train remains in the upshift position with the AFL fluid pressure acting on the 2-3 shift valve. In addition to its operation third gear, the 2-3 shift valve directs servo feed fluid into the 3-4 accumulator fluid circuit.

3-4 Accumulator Assembly

3-4 accumulator fluid pressure moves the 3-4 accumulator piston against spring force and orificed accumulator fluid pressure. This action absorbs initial 4th clutch apply fluid pressure in order to cushion the 2-4 band apply. Remember that both of the 3-4 accumulator and 4th fluid circuits are fed by servo feed fluid. As 3-4 accumulator fluid fills the accumulator, any air in the system will exhaust through office #19. This piston movement forces some orificed accumulator fluid out of the 3-4 accumulator assembly.

3-4 Accumulator Checkball (#1)

The accumulator fluid forced from the accumulator unseats the #1 checkball and enters the accumulator fluid circuit. This fluid is routed to the accumulator valve. This is shown by the arrow directions in the fluid circuit.

Accumulator fluid forced from the 3-4 accumulator is orificed to the end of the accumulator valve. This fluid pressure, in addition to spring force and torque signal fluid pressure, regulates the exhaust of excess accumulator fluid pressure through the middle of the valve. This regulation helps control the 2-4 band apply feel.

The solenoid remains open and routes AFL fluid into the 3-2 signal fluid circuit. 3-2 signal fluid pressure holds the 3-2 control valve against spring force, thereby blocking the 3rd accumulator and 3-4 clutch fluid circuits.

When operating conditions are appropriate, the PCM energizes the normally open TCC solenoid valve. This closes the solenoid, blocks the converter feed fluid from exhausting, and creates pressure in the converter feed fluid circuit at the converter clutch apply valve and TCC solenoid valve.

Converter Clutch Apply Valve

Converter feed fluid pressure moves the valve against spring force and into the apply position. In this position, release fluid is open to an exhaust port, and regulated apply fluid fills the apply fluid circuit. Converter feed fluid is routed through the converter clutch apply valve to feed the cooler fluid circuit.

Release fluid from behind the pressure plate exhausts through the end of the turbine shaft. Apply fluid pressure is routed between the converter hub and stator shaft where it enters the torque converter. This fluid applies the converter clutch against the converter cover and keeps the converter filled with fluid.

TCC Apply Checkball (#9)

Release fluid, exhausting from the converter, seats the #9 checkball located in the end of the turbine shaft, and is orificed around the ball. Orificing the exhausting release fluid controls the converter clutch apply rate, along with the TCC PWM solenoid valve.

TCC PWM Solenoid Valve

The torque converter clutch pulse width modulation (TCC PWM) solenoid valve controls the regulated apply valve position. This is done through the use of pulse width modulation (duty cycle operation). The solenoid duty cycle is controlled by the PCM in relation to vehicle operating conditions and regulates actuator feed limit (AFL) fluid into the CC signal circuit, through the #9 orifice, and to the isolator valve. This controls line pressure flow through the regulated apply valve, into the regulated apply circuit, and provides a smooth engagement of the TCC.

Scheme 37

Overdrive Range, 4-3 Downshift

When the transmission is operating in fourth gear, a forced 4-3 downshift occurs if there is a significant increase in throttle position. At minimum throttle, the vehicle speed decreases gradually (coastdown) and the PCM commands a 4-3 downshift. The PCM also initiates a forced 4-3 downshift when the throttle position remains constant but engine load is increased, such as driving up a steep incline. To achieve a 4-3 downshift, the PCM de-energizes the 1-2 shift solenoid valve and the following changes occur to the transmission's electrical and hydraulic systems

De-energized by the PCM, the normally open solenoid opens and signal A fluid exhausts through the solenoid.

As in Fourth gear, D432 fluid pressure and spring force hold the valve in the upshift position.

With the signal A fluid pressure exhausted, the spring force moves the valve into the downshift position. In this position, the valve blocks the 3-4 signal fluid and the 4th signal fluid exhausts past the valve.

These valves control the timing of the 2-4 band release. With the 4th signal fluid pressure exhausted, the 3-4 accumulator fluid pressure moves the 3-4 relay valve into the third gear position. This opens the 3-4 accumulator fluid to an orificed exhaust (#5) past the 3-4 relay valve (shown by red arrows). Because the exhaust is orificed, the 3-4 accumulator fluid pressure momentarily holds the 4-3 sequence valve against spring force before completely exhausting.

When the exhausting 3-4 accumulator fluid pressure decreases sufficiently, the spring force moves the 4-3 sequence valve into the third gear position as shown. This opens both the 3-4 accumulator and the 4th fluid circuits to a quick exhaust past the 4-3 sequence valve. In this position the valve blocks the 2nd fluid from entering the servo feed fluid circuit.

The 4th fluid exhausts from the 4th apply piston in the servo assembly. The apply pin spring moves the 4th apply piston and the apply pin in order to release the band from the reverse input drum and shift the transmission into third gear.

The 3-4 accumulator fluid exhausts from the 3-4 accumulator piston. The orificed accumulator fluid pressure and the spring force move the piston into a third gear position.

As the accumulator fluid fills the 3-4 accumulator, it seats the #1 checkball and is forced through orifice #18. This orifice controls the rate at which accumulator fluid pressure fills the 3-4 accumulator and the 3-4 accumulator fluid exhausts from the accumulator assembly.

Biased by torque signal fluid pressure and spring force, the accumulator valve regulates the D-4 fluid into the accumulator fluid circuit.

This solenoid remains de-energized as in fourth gear and the signal B fluid exhausts through the solenoid.

The AFL fluid pressure at the 2-3 shift valve holds the valves in the upshift position. This allows the servo feed fluid to exhaust through the valve, into the 3-4 accumulator fluid circuit and past the 4-3 sequence valve.

The PCM de-energizes the TCC solenoid valve, and operates the duty cycle of the TCC PWM solenoid valve to release the converter clutch for a smooth disengagement, prior to initiating the 4-3 downshift.

Remember that the PC solenoid valve continually adjusts the torque signal fluid pressure in relation to the various PCM input signals (mainly the throttle position).

Scheme 38

Overdrive Range, 3-2 Downshift

Similar to a forced 4-3 downshift, a forced 3-2 downshift can occur because of minimum throttle (coastdown conditions), heavy throttle or increased engine load. In order to achieve a forced 3-2 downshift, the PCM energizes the 2-3 shift solenoid valve and the following changes occur

Energized by the PCM, the normally open solenoid closes and blocks the signal B fluid from exhausting through the solenoid. This creates pressure in the signal B fluid circuit at the solenoid end of the 2-3 shift valve.

The signal B fluid pressure from the shift solenoid moves both valves to the downshift position against AFL fluid pressure acting on the 2-3 shift valve. This causes the following changes

1. The AFL fluid is blocked from the D432 fluid circuit and the D432 fluid exhausts past the 2-3 shuttle valve.
2. The 2nd fluid is blocked from feeding the 3-4 signal fluid circuit and the 2nd fluid is routed into the servo feed fluid circuit.
3. The 3-4 signal fluid is exhausted past the valve. The 3-4 clutch fluid and the 3rd accumulator fluid, which were fed by the 3-4 signal fluid, also exhaust.

The 3-4 clutch fluid exhausts from the piston and the 3-4 clutch plates are released.

Exhausting 3-4 clutch fluid seats the #4 checkball and is forced through orifice #13. This orifice controls the 3-4 clutch fluid exhaust and the 3-4 clutch release rate.

The 3rd accumulator fluid exhausts from the servo assembly. The 2nd clutch fluid pressure moves the 2nd apply piston against the servo return spring force in order to move the apply pin and apply the 2-4 band.

3-2 Downshift Valve and 1-2 Upshift Checkball (#8)

The 3-4 clutch fluid exhausts from the valve and the spring force moves the valve into the second gear position. However, before the spring force overcomes the exhausting 3-4 clutch fluid pressure, the 2nd fluid feeds the 2nd clutch fluid circuit through the valve. This bypasses the control of orifice #16 at the #8 checkball and provides a faster 2-4 band apply. Remember that the #8 checkball and orifice #16 are used to help control the 2-4 band apply during a 1-2 upshift.

Downshift Timing and Control

At higher vehicle speeds, the 2-4 band apply must be delayed to allow the engine speed RPM to increase sufficiently for a smooth transfer of engine load to the 2-4 band. Therefore, exhaust of the 3rd accumulator fluid must be delayed. However, at lower speeds the band must be applied quickly. In order to provide for the varying requirements for the 2-4 band apply rate, the exhausting 3rd accumulator fluid is routed to both the 3rd accumulator checkball (#2) and the 3-2 control valve.

The exhausting 3rd accumulator fluid seats the #2 checkball and is forced through orifice #12. This fluid exhausts through the 3-4 clutch and the 3-4 signal fluid circuits and past the 2-3 shift valve. Orifice #12 slows the exhaust of the 3rd accumulator fluid and delays the 2-4 band apply rate.

These components are used to increase the exhaust rate of 3rd accumulator fluid, as needed, depending on the vehicle speed.

The 3-2 control solenoid valve is a normally closed On/Off solenoid controlled by the PCM. The PCM controls the solenoid state during a 3-2 downshift according to vehicle speed.

Low Speed

1. At lower vehicle speeds, the PCM operates the 3-2 control solenoid valve in the Off position.
2. In the Off position the solenoid blocks actuator feed limit fluid pressure from the 3-2 control valve.
3. With no actuator feed limit fluid pressure, the 3-2 control valve spring force keeps the valve open to allow a faster exhaust of 3rd accumulator fluid through orifice #14 into the 3-4 clutch fluid circuit.
4. A faster exhaust of the 3rd accumulator exhaust fluid provides a faster apply of the 2-4 band, as needed at lower vehicle speeds.

High Speed

1. At high vehicle speed, the PCM operates the 3-2 control solenoid valve in the On position allowing actuator feed limit fluid to pass through the solenoid. This pushes the 3-2 control valve into the closed position.
2. This action permits a slow apply of the 2-4 band by blocking off 3rd accumulator exhaust fluid from entering the 3-4 clutch fluid circuit through orifice #14.
3. This allows the engine speed to easily come up to the necessary RPM before the 2-4 band is applied.

After the downshift is completed, the #7 checkball unseats and allows the residual fluid in the 3rd accumulator fluid circuit to exhaust.

Remember that the PC solenoid valve continually adjusts torque signal fluid in relation to the various PCM input signals (mainly the throttle position).

Scheme 39

Manual Third Gear

A manual 4-3 downshift is available to increase vehicle performance when the use of only three gear ratios is desired. Manual Third gear range also provides engine braking in Third gear when the throttle is released. A manual 4-3 downshift is accomplished by moving the selector lever into the Manual Third (D) position. This moves the manual valve and immediately downshifts the transmission into Third gear. Refer to Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied for a complete description of a 4-3 downshift. In Manual Third, the transmission is prevented, both hydraulically and electronically, from shifting into Fourth gear. The following information explains the additional changes during a manual 4-3 downshift as compared to a forced 4-3 downshift.

The selector lever moves the manual shaft and manual valve into the Manual Third position (D). This allows line pressure to enter the D3 fluid circuit.

D3 fluid is routed to the TFP manual valve position switch and opens the normally closed D3 fluid pressure switch. The combination of the opened D3 switch and the closed D4 switch signals the PCM that the transmission is operating in Manual Third.

When Manual Third is selected, the PCM de-energizes the 1-2 SS valve to immediately downshift the transmission into Third gear. This electronically prevents Fourth gear.

D3 fluid pressure assists spring force to keep the valve in the downshifted position against the signal A fluid circuit. In this position, the valve blocks 3-4 signal fluid and the 4th signal fluid circuit is open to an exhaust port past the valve. Therefore, with D3 fluid pressure assisting spring force, Fourth gear is hydraulically prevented.

With the 2-3 SS valve de-energized and open, actuator feed limit (AFL) fluid acting on the 2-3 shift valve holds both valves in the upshifted position. This allows D3 fluid to feed the overrun fluid circuit through the 2-3 shift valve.

Overrun Clutch Feed Checkball (#5)

Overrun fluid pressure seats the ball against the empty D2 fluid circuit.

Overrun Clutch Control Checkball (#6)

Overrun fluid pressure seats the #6 checkball and is orificed (#20) to fill the overrun clutch feed fluid circuit. This orifice controls the overrun clutch apply rate.

4th signal fluid pressure is exhausted from the end of the 3-4 relay valve. Overrun clutch feed fluid pressure assists spring force and closes both valves. This allows overrun clutch feed fluid to flow through the 4-3 sequence valve and fill the overrun clutch fluid circuit.

Overrun Clutch Piston

Overrun clutch fluid pressure moves the piston to apply the overrun clutch plates. The overrun clutch plates provide engine compression braking in Manual Third - Third Gear.

Overrun Clutch Air Bleed Checkball

This ball and capsule is located in the overrun clutch fluid circuit in the oil pump. It allows air to exhaust from the circuit as fluid pressure increases and also allows air into the circuit to displace the fluid when the clutch releases.

In order to achieve the highest fuel efficiency, the overrun clutch is applied during vehicle coast and braking. With the transmission in overdrive and either second or third gear, the overrun clutch is applied, allowing power to be transferred back through the torque converter to the electric machine and engine.

With the transmission in the D4 range and in either third or second gear, the M33 model applies the overrun clutch in order to maximize fuel efficiency during vehicle coast and braking. In this state, vehicle inertia is used to drive the engine and the electrical machine through the transmission. While in D4 third gear, the 2-3 SS valve is de-energized and the 2-3 shift valve train is in the upshift position. However, D3 oil is not available to apply the overrun clutch. In order to apply the overrun clutch, the spacer plate is used to redirect D2 oil to the overrun clutch circuit through the 2-3 valve train.

In D4 second gear, the 2-3 SS valve is energized and the 2-3 shift valve train is in the downshift position normally allowing overrun clutch circuit to exhaust. With the spacer plate redirecting the D2 oil, the overrun clutch can be applied.

Fluid pressure, from the automatic transmission secondary fluid pump assembly, unseats the ball check valve to allow fluid flow to the manual valve, where it is directed to the overrun clutch hydraulic circuit. The check valve prevents fluid, from the main transmission oil pump, from flowing into the secondary fluid pump.

Torque Converter Clutch and Torque Converter Clutch PWM Solenoid Valve

The PCM de-energizes the TCC solenoid valve and operates the duty cycle of the TCC PWM solenoid valve to release the converter clutch prior to downshifting, (assuming the converter clutch is applied in Overdrive Range-Fourth Gear when Manual Third is selected). The PCM will re-apply the converter clutch in Manual Third-Third Gear when proper driving conditions have been met.

The PC solenoid valve operates in the same manner as Overdrive Range, regulating in response to throttle position and other vehicle operating conditions.

Manual Third - First and Second Gears: Overrun Clutch Released

In Manual Third, the transmission upshifts and downshifts normally between First, Second and Third gears. However, in First and Second gears, the 2-3 SS valve is energized and the 2-3 shift valve train is in the downshifted position. The 2-3 shift valve blocks D3 fluid from entering the overrun fluid circuit and opens the overrun fluid circuit to an exhaust port at the valve. This prevents overrun clutch apply and engine compression braking in Manual Third-First and Second Gears.

Scheme 40

Manual Second Gear

A manual 3-2 downshift can be accomplished by moving the gear selector lever into the Manual Second (2) position when the transmission is operating in third gear. This causes the transmission to shift immediately into second gear regardless of vehicle operating conditions. Also, the transmission is prevented from operating in any other gear, first, third or fourth. The following information explains the additional changes during a manual 3-2 downshift, as compared to a forced 3-2 downshift. Some vehicles in manual second gear will start out in first gear, while other vehicles will have a second gear start. Refer to the owners manual for specific applications.

The selector lever moves the manual shaft and the manual valve into the manual second (2) position. This allows the line pressure to enter the D2 fluid circuit.

The D2 fluid is routed to the TFP manual valve position switch where it opens the normally closed D2 fluid pressure switch. With the D2 and the D3 pressure switches closed and the D4 pressure switch open, the TFP manual valve position switch signals the PCM that the transmission is operating in manual second.

The PCM energizes the 2-3 SS valve and the AFL fluid pressure holds the 2-3 shift valve in the downshift position. This electronically prevents operation of the third and fourth gears.

The D2 fluid is routed between the 2-3 shuttle and the 2-3 shift valves and causes the following

1. Regardless of the operating conditions, the D2 fluid pressure holds the 2-3 shift valve in the downshift position against the AFL fluid pressure.
2. The 2nd fluid is blocked from entering the 3-4 signal fluid circuit and the 3-4 signal fluid circuit is open to an exhaust port at the valve.
3. The 3-4 clutch cannot apply with the 3-4 signal fluid exhausted. Therefore, third and fourth gears are hydraulically prevented.
4. The 2nd fluid feeds the servo feed fluid circuit, but the 2nd fluid circuit has no function in manual second.
5. The AFL fluid is blocked by the 2-3 shift valve and the D432 fluid circuit is exhausted through the valve.
6. The overrun fluid is exhausted through the 2-3 shuttle valve.

The 1-2 SS valve is OFF, the signal A fluid exhausts through the solenoid and the spring force holds the valve in the upshifted position.

First Gear Prevented

The prevention of first gear is controlled electronically by the PCM through the 1-2 SS valve. The PCM keeps the 1-2 SS valve de-energized, regardless of the vehicle operating conditions when the TFP manual valve position switch signals manual second gear range. This keeps signal A fluid exhausted and the spring force holds the 1-2 shift valve in the upshift position.

Orificed D2 fluid pressure seats the #5 checkball against the empty overrun clutch fluid circuit. This is done simultaneously with the overrun clutch fluid exhausting so that there is a continuous fluid supply to the overrun clutch feed fluid circuit.

A continuous supply of fluid pressure is routed to the piston in order to keep the overrun clutch plates applied.

Torque Converter Clutch

The converter clutch is released prior to downshifting into manual second-second gear. Under normal operating conditions, the TCC will not apply in second gear.

The PCM output signal to the PC solenoid valve increases the operating range of torque signal fluid pressure in manual second. This provides the increased line pressure for the additional torque requirements during the engine compression braking and increased engine loads.

Scheme 41

Manual First Gear

A manual 2-1 downshift can be accomplished by moving the gear selector lever into the manual first (1) position when the transmission is operating in second gear. The downshift to first gear is controlled electronically by the PCM. The PCM will not energize the 1-2 shift solenoid valve to initiate the downshift until the vehicle speed is below approximately 48 to 56 km/h (30 to 35 mph). Above this speed, the transmission operates in a manual first-second gear state. The following text explains the manual 2-1 downshift.

The selector lever moves the manual shaft and the manual valve into the manual first (1) position. This allows the line pressure to enter the Lo fluid circuit.

Lo fluid is routed to the TFP manual valve position switch where it closes the normally open lo pressure switch. The addition of the lo pressure switch being closed signals to the PCM that manual first is selected.

In both first and second gears, this solenoid is energized and maintains the signal B fluid pressure at the solenoid end of the 2-3 shift valve train.

Held in the downshift position by the signal B fluid pressure from the solenoid, the valve train blocks the AFL fluid from entering the D432 fluid circuit. The D432 fluid circuit is open to exhaust past the valve.

Below approximately 48 to 56 km/h (30 to 35 mph) the PCM energizes the normally open solenoid. This blocks the signal A fluid pressure from exhausting through the solenoid and creates the pressure in the signal A fluid circuit. Above this speed, the PCM keeps the solenoid de-energized and the transmission operates in manual first-second gear.

Signal A fluid pressure moves the valve against the spring force and into the downshift position. In this position, Lo fluid from the manual valve is routed into the Lo/1st fluid circuit and D4 fluid is blocked from entering the 2nd fluid circuit. The 2nd fluid exhausts through an orifice and an annulus exhaust port past the valve. This orifice (#26) helps control the 2-4 band release during a 2-1 downshift.

The 2nd clutch fluid, which was fed by the 2nd fluid, exhausts from the servo. This allows the spring force from the servo cushion and the servo return springs to move the 2nd apply piston and apply the pin to release the 2-4 band. These spring forces help control the 2-4 band release.

1-2 Accumulator Assembly

The 2nd clutch fluid also exhausts from the 1-2 accumulator assembly. The spring force and the accumulator fluid pressure move the accumulator piston to assist the 2nd clutch fluid exhaust.

As the accumulator fluid is filling the 1-2 accumulator assembly, the accumulator valve regulates the D4 fluid into the accumulator fluid circuit. This regulation, biased by torque signal fluid pressure and spring force, helps control the movement of the 1-2 accumulator piston. The 2nd clutch fluid exhaust, and the 2-4 band release.

1-2 Upshift Checkball (#8)

Exhausting the 2nd clutch fluid pressure unseats the ball and is routed through the 2nd fluid circuit.

The Lo/1st fluid is regulated through the lo overrun valve and into the Lo/reverse fluid circuit in order to control the lo and reverse clutch apply.

Lo and Reverse Piston

The Lo/reverse fluid pressure acts on the inner area of the piston in order to move the piston and in order to apply the lo and reverse clutch plates.

Overrun Clutch Applied

The overrun clutch remains applied in manual first in order to provide engine compression braking.

Similar to manual second, the PCM output signal to the PC solenoid valve increases the operating range of the torque signal fluid pressure. This provides the increased line pressure for the additional torque requirements during the engine compression braking and the increased engine loads.

3-2 Downshift Control Solenoid Valve and the 3-2 Control Valve

In first gear the solenoid is OFF, the AFL fluid is blocked by the solenoid, and the 3-2 signal fluid exhausts through the solenoid and the spring force opens the 3-2 control valve.

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Special Tools (Unit Repair)

Special Tools (Unit Repair) Illustration Tool Number/Description J 7004-1 Universal Remover J 8001 Dial Indicator Set J 8092 Driver Handle J 8433 Two Jaw Puller J 8763-02 Holding Fixture and Base J 21366 Converter Holding Strap J 21368 Pump Body and Cover Alignment Band J 21426 Rear Seal Installer J 21427-01 Speedometer Gear Puller Adapter J 21465-01 Bushing Service Set J 21465-2 Pump Cover Bushing Installer J 21465-15 Sun Gear and Stator Shaft Bushing Remover J 22269-01 Accumulator and Servo Piston Remover J 23062-14 Bushing Remover J 23327-1 Forward Clutch Spring Compressor (Bridge) J 23456 Booster and Clutch Pack Compressor J 23907 Slide Hammer with Bearing Adapter J 24773-A Oil Pump Remover J 25016 Pump Seal and Speedometer gear Installer J 25018-A Clutch Spring Compressor Adapter J 25019 Bushing Service Set J 25019-4 Direct Clutch Bushing Remover J 25019-9 Bushing Installer J 25019-14 Stator Pump Bushing Remover J 25019-16 Bushing Remover J 25022-A End Play Fixture Adapter J 25025-1 Dial Indicator Mounting Post J 25025-5 Guide Pins J 25025-7A Dial Indicator Post J 26744-A Seal Installer J 26900-13 Magnetic Indicator Base J 29369-2 Bushing and Bearing Remover - 2-3 in J 29714-A Servo Cover Depressor J 29837-A Output Shaft Support Fixture J 29882 Overrun Clutch Inner Seal Protector J 29883 Forward Clutch Inner Seal Protector J 33037 2-4 Intermediate Band Apply Pin Gage J 34196-B Transmission Bushing Service Set J 34627 Snap Ring Remover and Installer J 34725 End Play Checking Adapter J 35138 Converter End Play Checker J 36352 Speed Sensor Rotor Installer Kit J 36352-4 Speed Sensor Rotor Installation Depth C Washer J 36352-6 Speed Sensor Rotor Installation Tube J 36418-1B Turbine Shaft Seal Installer J 36418-2A Turbine Shaft Seal Sizer J 36850 Transjel Lubricant J 37789-A Pump Remover and Installer J 38735-3 Pusher J 39119 Oil Pump Remover/Installer Adapter J 39195 Converter End Play Tool J 39855 Stator Shaft Seal Installer J 41510 T-50 Plus Bit J 41778-1 Pump Body Bushing Installer/Remover J 41778-2 Pump Body Bushing Position Stop J 42198 Case Rear Oil Seal Installer J 42628 Disc J 43205 End Play Fixture Adapter (300 mm converter) J 44571-1 Reverse Input Clutch Piston Installer

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See also:
• Special Tools and Equipment
• End Play Specifications
• Low and Reverse Clutch Spacer Plate Selection
• Forward Clutch Backing Plate Selection
• Third and Fourth Clutch Backing Plate Selection
• Reverse Input Clutch Backing Plate Selection
• Oil Pump Rotor and Slide Measurement
• Secondary Fluid Pump Assembly Removal (M33 Model Only)
• Overdrive Range, Fourth Gear - Torque Converter Clutch (TCC) Applied