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

2-4 SERVO ASSEMBLY

Install Servo Cover Compressor (J-29714-A) on oil pan. (Scheme 422) Compress servo cover. Remove retaining ring, servo cover and "O" ring. Remove 2-4 servo assembly. (Scheme 421)

Removing Servo Assembly. Scheme 421

Scheme 422

3RD ACCUMULATOR RETAINER & BALL ASSEMBLY

1. Check 3rd accumulator retainer and ball assembly before removing it. DO NOT remove check valve unless it is leaking. Install servo assembly in bore. Install servo cover and retaining ring. (Scheme 422) Pour clean solvent in bore. Inspect for leaks in transmission case. Replace check valve assembly if it leaks. (Scheme 423) Remove servo assembly.
2. For check valve removal, install No. 4 screw extractor in check valve assembly. Remove check valve. Ensure bore is free of burrs. Installation tool must be made to ensure proper installation depth is obtained. Using a 3/8" O.D. rod, scribe indicator mark at 1.653" (41.98 mm) from end of rod. Install check valve until scribe mark on rod is flush with case. (Scheme 423) Ensure slot in retainer is completely open. Observe 3rd accumulator retainer and ball assembly in 2-4 band servo bore.

Scheme 423

Disassembly

1. Remove reverse input clutch drum-to-oil pump thrust washer, pump-to-case gasket and pump-to-case oil seal ring from pump assembly. (Scheme 424) Remove pump cover retaining bolts. Separate pump cover from pump body. (Scheme 425)
2. Using needle-nose pliers, compress pump slide spring. Remove from pump by pulling straight out. Remove pump vane rings, pump vanes, pump rotor and rotor guide from pump pocket.
3. Remove slide from pump pocket. Remove slide seal and seal support from pump slide. (Scheme 426) Remove pivot pin and pivot pin spring. Remove seal ring and "O" ring from pump slide. Remove seal retainer and seal from pump body.
4. Check condition of pump bushing. If bushing is in good condition, do not remove it. Push inward on converter clutch valve stop to compress spring. Remove snap ring. Remove valve stop, converter clutch apply valve and springs.
5. Using small punch, remove pressure relief spring retaining rivet. Remove relief spring and check ball. Remove oil screen and "O" ring from pump cover. Remove reverse boost valve sleeve. Remove reverse boost valve, pressure regulator valve spring and pressure regulator valve.

Scheme 424

Scheme 425

Scheme 426

Reassembly

1. Install "O" ring and seal ring in groove on back side of pump slide. Retain seal ring using petroleum jelly. Install pivot pin and spring in pump body. Install pump slide. Notch in pump slide must align with pivot pin hole and with flat oil seal ring facing downward in pump pocket. Install slide seal and support. (Scheme 427)
2. Install pump vane ring into pump pocket. Coat rotor guide with petroleum jelly. Install rotor guide on rotor. Install rotor and guide into pump pocket with guide toward pump pocket. Install vanes in rotor. Install vane guide ring. Compress pump slide spring and install into pump pocket. All parts must be even with pump body surface. Install "O" ring on pump screen, and install screen in pump cover with "O" ring end out.
3. Install oil seal in pump body. Install seal retainer. Install pressure relief check ball and spring in pump cover. Install retaining rivet. Install converter clutch valve springs and converter clutch valve. Install valve stop and snap ring. Install pressure regulator valve and spring in pump cover. (Scheme 426)
4. Coat reverse boost valve with petroleum jelly. Install reverse boost valve in boost valve sleeve with small end first. Install reverse boost valve sleeve in pump cover.
5. Install pump cover on pump body. Install retaining bolts finger tight. Align pump body and cover using Alignment Strap (J-21368). (Scheme 428) Place bolt through pump-to-case bolt hole. Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000). Remove alignment strap. Position pump-to-case gasket on pump, and retain with petroleum jelly.
6. Install oil seal rings on stator hub. Place Stator Shaft Seal Installer (J39855-1) over oil pump stator hub (stator support). (Scheme 429) Set height of installer tool to just above seal groove. Push seal ring over installer tool using Seal Pusher (J38735-3). Install remaining seal rings. Place Stator Shaft Seal Sizer (J39855-2) over stator hub and leave until oil pump installation.
7. Install pump-to-case oil seal on cover. Ensure seal is not twisted. Coat seal with ATF. Install pump-to-drum thrust washer. Ensure tangs on washer engage with holes in hub.

Scheme 427

Scheme 428

Scheme 429

1. Remove the reverse input clutch housing and drum assembly from the input clutch assembly. Remove the stator/selective washer bearing assembly. Remove the selective thrust washer. Remove the 3rd and 4th clutch backing plate retainer ring. Remove all 3rd and 4th clutch plates. Remove the 3-4 clutch boost spring assemblies. see scheme 28 NOTE: The 3rd and 4th clutch plate stack is different for 2.2L models. The M30 RPO 3-4 Clutch plate stack up is application specific. The stack up on a 2.2L S/T platform is 5 fiber plates, and 6 fiber plates on all other models. The M32 RPO (heavy-duty design) uses 7 fiber plates. These fiber plates are thinner thickness which can not be used in a M30 stack up. M32 fiber plates must not be used in a M30 design.
2. Remove the forward clutch backing plate retainer ring (651). Remove the forward clutch selective backing plate (650). Remove the forward clutch sprag assembly. (Scheme 432)
3. Remove all forward clutch plates (646, 648, 649A, 649B). Remove the input sun gear bearing assembly (637). Remove the input housing to output shaft seal (636). Remove all overrun clutch plates (645A, 645B). (Scheme 431)
4. Install the clutch spring compressor and adapter. Compress the overrun clutch spring using the clutch spring compressor and press. Remove the overrun clutch spring retainer snap ring (635). (Scheme 430)
5. Remove the overrun clutch spring assembly (634). Remove the overrun clutch piston (632). Remove the forward clutch piston (630). Remove the forward clutch housing (628). Remove the 3rd and 4th clutch spring assembly (626). Remove the 3rd and 4th clutch apply ring (625). Remove the 3rd and 4th clutch piston (623). (Scheme 433)

Scheme 430

Scheme 431

Scheme 432

Scheme 433

Scheme 434

Scheme 435

1. Place input clutch housing with turbine shaft downward. Install 3-4 piston seals with lips facing away from hub. Install 3-4 piston in input housing.
2. Install 3-4 clutch apply ring. Install "O" ring seal in input clutch housing. Install forward clutch housing. Install seals on forward clutch piston with lips facing away from tangs.
3. Install forward clutch piston in forward clutch housing. Install 3-4 spring on 3-4 clutch apply ring. Install forward clutch assembly on 3-4 spring assembly. Align forward clutch piston legs with tangs of 3-4 apply ring. Install Seal Protector (J-29883) on input housing.
4. Install 3-4 apply ring and forward clutch assembly in input clutch housing. Hold apply ring tangs while installing. DO NOT allow forward clutch piston to separate from assembly. Ensure assembly is firmly seated.
5. Install Seal Protector (J-29883) on input housing. Install overrun clutch piston with hub facing upward. If fully seated, overrun piston should be 3/16" below top of snap ring groove in input housing hub. Install spring assembly on overrun clutch piston. Compress springs, and install snap ring. Install input housing seal.
6. Install 4 overrun clutch plates, starting with steel plate. Align wide notches with case lugs. Install remaining clutch plates, alternating steel and composition plates.
7. Install bearing assembly on input clutch hub. Bearing inner race must face input housing hub. Ensure bearing is centered. Align clutch plate tabs. Install forward clutch sprag assembly in input housing. Align overrun clutch hub with clutch plates.
8. Install forward clutch apply plate in input housing. Install forward clutch waved plate. Ensure all plates are aligned with input housing tangs. Starting with steel plate, install clutch plates, alternating steel and composition plates. Install backing plate and snap ring. (Scheme 434)
9. Using 2 feeler gauges, measure clearance between backing plate and snap ring. (Scheme 435) Ensure clearance is as specified. See «FORWARD CLUTCH CLEARANCE SPECIFICATIONS»(ref-156199-S04932340882003071000000) table. If clearance is not as specified, install proper size backing plate with chamfered side upward. See «FORWARD CLUTCH BACKING PLATE SPECIFICATIONS»(ref-156199-S41797962242003071000000) table. Install snap ring. FORWARD CLUTCH CLEARANCE SPECIFICATIONS Application Clearance - In. (mm) 9.650" (245 mm) Converter.030-.069 (.76-1.75) 258 mm Converter (1) 298 mm Converter.034-.074 (.86-1.88) 300 mm Converter.034-.074 (.86-1.88) (1) Specification is not available from manufacturer. FORWARD CLUTCH BACKING PLATE SPECIFICATIONS Identification Thickness - In. (mm) A.274-.278 (6.96-7.06) B.250-.255 (6.35-6.48) C.227-.232 (5.77-5.89) D.205-.208 (5.21-5.28) E.180-.185 (4.57-4.70)
10. Install apply plate and 3-4 clutch plates. (Scheme 436) Install 3-4 clutch booster spring assemblies. (Scheme 437) Install backing plate with chamfered side upward. Install retaining snap ring. Using feeler gauge, measure clearance between backing plate and first composition plate. (Scheme 438) Clearance should be.035-.083" (.89-2.11 mm).
11. If clearance is not as specified, select proper backing plate to obtain correct clearance. See «3-4 BACKING PLATE SPECIFICATIONS»(ref-156199-S33224826232003071000000) table. Air check all clutches at feed holes in turbine shaft. (Scheme 439)
12. During overrun clutch test, air pressure will blow past forward clutch piston seals and exit out forward clutch feed hole in turbine shaft. Turbine shaft seals require sizing and should be installed before oil pump installation. Position Seal Installer (J-36418-1B) on input shaft. (Scheme 440) Adjustment screw in seal installer must be adjusted to obtain correct height for each seal installation. Install 4 turbine shaft seals.

3-4 BACKING PLATE SPECIFICATIONS

Scheme 436

Scheme 437

Scheme 438

Scheme 439

Scheme 440

1. Remove the overrun clutch hub retaining snap ring (638). Remove the overrun clutch hub (639). Remove the forward sprag clutch inner race and input sun gear assembly (640). see scheme 51
2. Remove the sprag assembly retainer rings (643). see scheme 52

1. Install roller clutch assembly in low-reverse support. (Scheme 441) Place support in case with hub facing downward. Install inner race. Rotate inner race while pushing downward. Use care not to damage roller and springs during installation.
2. Ensure inner race is fully seated. Bottom tangs will be flush with carrier hub when fully seated. Inner race should rotate clockwise and lock counterclockwise with clutch hub downward. Insert support retainer spring into case between case lug and open notch in support.

Scheme 441

1. Remove 4th apply piston and housing from 2nd apply piston assembly. Remove return spring from apply pin. Install Piston Compressor (J-22269-01) on 2nd apply piston. (Scheme 443)
2. Compress 2nd servo apply piston assembly. Remove retainer ring. Separate 2nd apply piston, spring and retainer. Remove retainer ring, washer and spring from apply pin, and remove pin. Remove all oil seal rings. (Scheme 442)

Scheme 442

Scheme 443

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

1. Remove the manual valve (340). (Scheme 444)
2. Remove the forward accumulator cover bolts (364) and the forward accumulator cover (363). Remove the forward accumulator spring (356), forward accumulator piston (354), and the forward accumulator pin (355). Remove the low overrun valve spring (362) and the low overrun valve (361). Remove the coiled spring pin (360) and the bore plug (359). Remove the forward abuse valve spring (358) and the forward abuse valve (357). (Scheme 445)
3. Remove the solenoid retainer (395) and the 1-2 shift solenoid (367A). Remove the 1-2 shift valve (366) and the 1-2 shift valve spring (365). (Scheme 446)
4. Remove the solenoid retainer (395) and the 2-3 shift solenoid (367B). Remove the 2-3 shuttle valve (369) and the 2-3 shift valve (368). (Scheme 447)
5. Remove the coiled spring pin (360). Remove the 1-2 accumulator valve sleeve (372). Remove the 1-2 accumulator valve (371) and the 1-2 accumulator valve spring (370). (Scheme 448)
6. Remove the solenoid retainer bolt (364A) and the solenoid retainer (378). Remove the pressure control solenoid (377). Compress the actuator feed limit valve spring (375). Remove the bore plug retainer (395) and release the spring slowly. Remove the bore plug (376). Remove the actuator feed limit valve spring (375) and the actuator feed limit valve (374). (Scheme 449)
7. Remove the solenoid retainer (395) and the 3-2 control solenoid (394). Remove the 3-2 control valve (391) and the 3-2 control valve spring (392). (Scheme 450)
8. Remove the bore plug retainer (395) and the bore plug (381). Remove the 3-2 downshift valve spring (390) and the 3-2 downshift valve (389). Remove the coiled spring pin (360) and the bore plug (359). Remove the reverse abuse valve spring (388) and the reverse abuse valve (387). (Scheme 451)
9. Remove the bore plug retainer (395) and the bore plug (381). Remove the 3-4 shift valve spring (386) and the 3-4 shift valve (385). (Scheme 452)
10. Remove the bore plug retainer (395) and the bore plug (381). Remove the regulator apply valve (380) and the regulator apply spring (397) and the isolator valve (398). (Scheme 453)
11. Remove the bore plug retainer (395) and the bore plug (381). Remove the 3-4 relay valve (384) and the 4-3 sequence valve (383) and the 4-3 sequence valve spring (382). (Scheme 454)

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

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

Scheme 444

Scheme 445

Scheme 446

Scheme 447

Scheme 448

Scheme 449

Scheme 450

Scheme 451

Scheme 452

Scheme 453

Scheme 454

TRANSMISSION REASSEMBLY

Note. To identify bushing, seal, thrust bearing and thrust washer locations and direction, refer to appropriate illustration. see scheme 85and see scheme 86.

REVERSE INPUT ASSEMBLY & INPUT CLUTCH

1. Install the selective thrust washer (616) on the input housing (621). Install the stator shaft/selective washer bearing assembly (615) on the input housing (621). The black race on the bearing goes toward the oil pump. Install the reverse input clutch assembly (605) on the input housing (621). Index the reverse input clutch plates with the input clutch hub. Make certain all clutch plates are fully engaged. (Scheme 455)
2. Install reverse and input clutch assemblies in transmission case as an assembly. Align 3-4 clutch plates of input assembly with input internal gear. Assembly is fully seated when reverse input clutch housing is just below oil pump face of case. (Scheme 456)

Scheme 455

Scheme 456

OIL PUMP ASSEMBLY

1. Ensure turbine shaft seals on input shaft have been sized using Seal Sizer (J-36418-2A). (Scheme 440) Install aligning pins in 2 opposing pump bolt holes in transmission case. Ensure thrust washer is installed on rear of oil pump. Thrust washer can be retained using petroleum jelly.
2. Remove input shaft Seal Sizer (J-36418-2A). Remove Stator Shaft Seal Sizer (J39855-2). Install oil pump into case, aligning filter and pressure regulator holes with holes in case. Install retaining bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000). Place transmission in a horizontal position.
3. Turbine shaft should rotate by hand. If turbine shaft will not rotate, loosen pump retaining bolts and attempt to rotate shaft again. If shaft now turns, reverse and input assemblies have not been indexed properly or some other assembly problem has occurred, such as thrust washer not positioned properly.
4. Check transmission end play. See «TRANSMISSION END PLAY CHECK»(ref-156199-S01335717432003071000000). Transmission end play should be.005-.036" (.13-.91 mm). Install torque converter. Ensure converter hub is aligned with oil pump. Install torque converter retaining strap to hold converter.

2-4 BAND & SERVO ASSEMBLY

1. Install 2-4 band in case. Align band anchor pin end with case pin hole. Install band anchor pin in case. see scheme 25 Ensure band anchor pin aligns with end of 2-4 band.
2. Install 2-4 servo assembly into case, and index apply pin on band end. Check for proper engagement of apply pin on band end. Recheck 2-4 servo apply pin selection to ensure correct pin is installed.
3. Remove 4th apply piston and return spring. (Scheme 442) Remove retainer ring, washer, apply pin spring and 2nd apply pin. Install Piston Compressor (J-22269-01) on 2nd apply piston. (Scheme 443)
4. Remove retainer ring, cushion spring and spring retainer. Install Band Apply Pin Tool (J-33037) and apply pin. (Scheme 457) Apply 100 INCH lbs. (11 N.m) torque.
5. White line on band apply tool should be within gauge slot if pin length is correct. If White line is not within gauge slot, inspect 2-4 band and reverse input drum for wear and damage during disassembly.
6. Servo pin length must be checked during reassembly. Servo pin is preset and must not be readjusted. Different length servo pins are available. See «SERVO PIN SPECIFICATIONS»(ref-156199-S32141446292003071000000) table. Select proper length servo pin. Reassemble 2-4 servo. Install servo cover and "O" ring. Compress cover and install cover retaining ring. Index ends of retaining ring with slot in case.

SERVO PIN SPECIFICATIONS

Scheme 457