Automatic Transmission - 4L60-E/4L65-E - Overhaul & Testing: Other Chevrolet Silverado 1500 HD

GEAR RATIOS

TRANSMISSION GEAR RATIOS

CONVERTER HOUSING

Mount transmission on bench using Holding Fixture (J-8763-02). Remove torque converter. Using 50 mm Torx Plus Bit (J-41510), remove converter housing bolts, and remove converter housing. (Scheme 458)

Removing Torque Converter. Scheme 458

EXTENSION HOUSING

Remove Vehicle Speed Sensor (VSS) retaining bolt. Remove speed sensor assembly and "O" ring. (Scheme 478) Remove extension housing and seal. Remove output shaft sleeve and "O" ring (if equipped). Remove speed sensor rotor from output shaft (if necessary). Install Gear Puller (J-21427-01) and Adapter (J-8433) on rotor. Pull rotor from output shaft. Install Output Shaft Support Fixture (J-29837-A) on output shaft. (Scheme 459)

Scheme 459

VALVE BODY, 1-2 & 3-4 ACCUMULATORS

Scheme 460

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

Scheme 467

Scheme 468

Scheme 469

1. Remove transmission oil pan. Remove oil filter and "O" ring. Ensure "O" ring is removed from transmission case. Remove electrical connectors from switches and solenoids, and mark for reassembly reference. (Scheme 460)Remove TCC PWM solenoid retainer clip. Remove solenoid. (Scheme 461)
2. Remove TCC solenoid bolts. (Scheme 462) Remove valve body bolts securing wiring harness. Remove TCC solenoid and allow wiring harness to hang over side of case. (Scheme 463) Remove transmission fluid pressure manual valve position switch. (Scheme 464) Remove detent spring bolt. Remove detent spring. (Scheme 465) Remove remaining valve body bolts. Note length and location of bolts for installation reference. (Scheme 466)
3. Note direction of manual valve link. Remove manual valve link from manual valve at valve body. (Scheme 467) Remove valve body. Note location of check balls on valve body. (Scheme 468)
4. Carefully remove accumulator cover retaining bolts, 1-2 accumulator cover and pin assembly. (Scheme 479) Remove 1-2 accumulator piston, seal and spring. Remove spacer plate beside 1-2 accumulator. Note check ball and filter locations. (Scheme 469) Remove spacer plates. Remove spring, 3-4 accumulator piston and pin. (Scheme 460): Locating Valve Body Solenoids (Scheme 461): Removing TCC PWM Solenoid (Scheme 462): Removing TCC Bolts (Scheme 463): Removing TCC Solenoid & Wire Harness (Scheme 464): Removing Transmission Fluid Pressure Assembly (Scheme 465): Removing Detent Spring Assembly (Scheme 466): Identifying Valve Body Bolt Location

OIL PUMP, INPUT CLUTCH & REVERSE CLUTCH

1. Ensure TCC solenoid assembly and oil filter are removed before oil pump removal. Remove turbine shaft "O" ring. Remove oil pump retaining bolts. Using Oil Pump Remover (J-37789-A) and Adapter (J-39119), pull oil pump assembly free from case. (Scheme 470)
2. Remove oil pump, seal and gasket. Remove reverse input clutch-to-pump thrust washer from pump. Remove band anchor pin from case. (Scheme 477)Lift out input housing, shaft assembly, reverse input clutch housing and drum assembly. (Scheme 471)

Scheme 470

Removing/Installing Input Clutch Assembly. Scheme 471

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

1. Remove 2-4 band assembly from case. (Scheme 472) Remove input sun gear. (Scheme 480)
2. Remove input carrier-to-output shaft retainer ring. (Scheme 473) Remove input carrier (planetary). Remove input carrier thrust bearing from reaction carrier shaft. (Scheme 474)
3. Remove input internal gear and reaction carrier shaft assembly. (Scheme 475) Remove reaction sun shell and thrust washer. (Scheme 476) Remove reaction sun gear, thrust washer, low-reverse roller clutch race and roller clutch. (Scheme 480)

Removing/Installing 2-4 Band Assembly. Scheme 472

Removing/Installing Input Carrier To Output Shaft Retainer. Scheme 473

Removing/Installing Input Carrier Assembly. Scheme 474

Removing/Installing Input Internal Gear & Reaction Carrier Shaft Assembly. Scheme 475

Removing Thrust Washer & Reaction Sun Shell. Scheme 476

Scheme 477

Scheme 478

Scheme 479

Scheme 480

LOW-REVERSE CLUTCH

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

1. Remove low-reverse support-to-case retaining snap ring. Remove output shaft support fixture. (Scheme 459) Push up on output shaft to loosen low-reverse clutch support. Remove support retainer spring from low-reverse support. Remove low-reverse support assembly and reaction carrier assembly (planetary). (Scheme 480) Remove output shaft.
2. Remove low-reverse clutch plates. Note locations of components. (Scheme 481) Remove internal reaction gear and thrust bearing. Remove internal reaction gear support-to-case thrust bearing. (Scheme 482)
3. Remove parking lock bracket retaining bolts. Remove lock bracket. Using screw extractor, remove shaft plug. Remove parking pawl shaft, parking pawl and return spring if necessary. (Scheme 484)
4. Using Clutch Spring Compressor (J-23327), compress low reverse clutch spring retainer. Remove spring retaining ring and low-reverse spring assembly. Remove low-reverse clutch piston by applying air pressure in case apply passage. (Scheme 483)

Scheme 481

Removing/Installing Internal Reaction Gear & Thrust Bearing. Scheme 482

Scheme 483

INNER MANUAL SHAFT LINKAGE

Remove manual shaft nut. Remove manual shaft and retainer. Remove parking lock actuator assembly and inner detent lever. Remove manual shaft seal from transmission case. (Scheme 484)

Scheme 484

LOW-REVERSE SUPPORT

VALVE BODY

1. Place transmission in a vertical position. Install seals on low-reverse clutch piston. Apply petroleum jelly to seals. Align and install piston with notch in bottom of transmission case (695). Ensure piston is fully seated and parking pawl aligns with opening in piston wall. (Scheme 485) Install the low and reverse clutch spring assembly (694). Using the Clutch Spring Compressor (J23327-1), compress the low and reverse clutch spring assembly (694). Using the Snap Ring Remover and Installer (J36850), install the low and reverse clutch retainer ring (693). (Scheme 486)
2. Coat bearing assembly with petroleum jelly. Install bearing assembly on case hub with outside bearing race toward case hub. Install internal reaction gear and support. Install bearing assembly onto support with outside bearing race toward support. Install oil deflector (if equipped) and reaction carrier assembly in case. (Scheme 480)
3. Place waved plate on work bench. Install 5 composition plates and 4 steel plates alternately, starting with composition plate. Install low-reverse support. Apply light pressure to low-reverse support. Do not flatten waved plate. Measure height of clutch pack from work bench to top of low-reverse support. (Scheme 487)
4. Using height dimension, determine proper selective spacer plate to be used. See «SPACER PLATE SELECTION»(ref-156199-S29089093402003071000000) table. SPACER PLATE SELECTION Measured Clutch Pack Height - In. (mm) (1) Identification Plate Thickness - In. (mm) 1.084-1.105 (27.53-28.07) None.066-.072 (1.67-1.85) 1.105-1.125 (28.07-28.58) "0".046-.052 (1.17-1.31) 1.064-1.084 (27.03-27.53) "1".087-.092 (2.19-2.34) (1) Clutch pack height is measured without spacer plate in position.
5. Place spacer plate between waved plate and first composition plate with identification facing upward. Measure overall height of clutch pack. Overall height should be 1.15-1.18" (29.2-29.9 mm). Install low-reverse clutch pack into transmission case. Ensure clutch plates align with splines of reaction carrier. Ensure steel plates are properly indexed in transmission case. (Scheme 488)
6. Install low-reverse support in case with hub downward. Install inner race by pushing downward while rotating until it is fully engaged. Bottom tangs will be flush with hub when fully installed. Install spring retainer in case between case lug and open notch in support. Install low-reverse snap ring. (Scheme 489)

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

REACTION & INPUT GEAR SETS

1. Install retainer ring on reaction sun gear (if removed). Install sun gear into reaction carrier. Install thrust washer on low-reverse clutch race. Install reaction sun gear shell on reaction sun gear.
2. Install thrust washer on reaction sun gear shell. Ensure thrust washer tangs engage on gear shell. Install input internal gear and reaction carrier shaft in sun gear shell. Carrier shaft splines must engage with reaction carrier. (Scheme 480)
3. Install thrust washer on reaction carrier shaft. Outer race must face toward reaction carrier shaft. Install output shaft in transmission. Ensure output shaft engages with all parts.
4. Install Output Shaft Support (J-29837-A). (Scheme 459) Adjust support so output shaft is positioned upward as far as possible. Install input carrier (planetary) assembly with hub end down on output shaft. Install NEW retainer ring on output shaft. Remove output shaft support. Install input sun gear, indexing gear end with input carrier pinions.

TRANSMISSION END PLAY CHECK

1. Install Pump Remover/End Play Fixture (J-24773-A) and End Play Adapter (J-25022-A) on end of turbine shaft. (Scheme 490) Clamp dial indicator on long bolt with indicator tip on end play fixture. Zero dial indicator.
2. Pull up on end play fixture. Measure transmission end play. Transmission end play should be.005-.036" (.13-.91 mm). If transmission end play is not within specification, selective thrust washer must be changed between oil pump and input housing. (Scheme 480) Install appropriate thrust washer, and recheck end play. See «OIL PUMP THRUST WASHER SPECIFICATIONS»(ref-156199-S16656892732003071000000) table.

OIL PUMP THRUST WASHER SPECIFICATIONS

Scheme 490

1. Install 3-4 accumulator piston pin in case. Install 3-4 piston seal on piston. Install 3-4 accumulator piston on pin. Legs of piston must face valve body.
2. Install 3-4 accumulator spring. Install oil screens in proper locations. (Scheme 491) (Scheme 469)for check ball and filter installation locations. Install alignment pins in transmission case to aid spacer plate and valve body installation. Install spacer plate gasket and spacer plate. Install spacer plate support.
3. Install 1-2 accumulator spring, oil seal ring and 1-2 accumulator piston. Install accumulator cover and bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000).
4. Coat check balls with petroleum jelly. Install check balls in proper locations in valve body. (Scheme 468)and (Scheme 469). Install manual valve link. Ensure manual valve link is properly seated in manual valve. (Scheme 467) Improper positioning may prevent vehicle operation in "D" range. NOTE: Improper positioning of throttle valve link will result in erratic shift points or high oil pressure.
5. Install valve body and retaining bolts. Ensure correct length and location of bolts. (Scheme 466) Install detent spring. Install detent spring bolt. Install transmission fluid pressure manual valve position switch. Install TCC solenoid. Install valve body bolts that secure wiring harness. Tighten all valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000).
6. Install TCC PWM solenoid. Install retainer clip. Install electrical connectors to switches and solenoids. (Scheme 460) Install oil filter and "O" ring. Install transmission oil pan.

Scheme 491

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

Scheme 492

Scheme 493