Automatic Transmission - 4L80-E/4L85-E - Overhaul: Other Chevrolet Silverado 1500

Low and Reverse Band Servo Piston Pin Check

Tools Required

1. J 21370-10 Band Apply Pin Gage. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 38737 Band Apply Pin Checking Tool. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 646

1. Install the J 21370-10 into the low and reverse band servo pin bore. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Position the J 38737 over the low and reverse band servo bore with the hex hub facing the parking pawl linkage. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Fasten the J 38737 to the case with two low and reverse band servo cover bolts (61). See «Special Tools»(ref-246429-S18893617282006122100000) . Tighten: Tighten the bolts to 24 N.m (18 lb ft).
4. Verify that the J 21370-10 moves freely in the J 38737 and in the low and reverse band servo pin bore. See «Special Tools»(ref-246429-S18893617282006122100000) .
5. In order to determine the correct low and reverse band servo piston pin length, tighten the hex hub of the J 38737 . See «Special Tools»(ref-246429-S18893617282006122100000) . Tighten: Tighten the hex hub of the J 38737 to 34 N. See «Special Tools»(ref-246429-S18893617282006122100000) .m (25 lb ft).
6. Observe the lands on the J 21370-10 in order to determine which land is even with the top edge of the J 38737 . See «Special Tools»(ref-246429-S18893617282006122100000) . Note the letter (A, B or C) stamped on the J 21370-10 . See «Special Tools»(ref-246429-S18893617282006122100000) .
7. Refer to the Low and Reverse Band Servo Piston Pin Specification chart, in the «Transmission General Specifications»(ref-246429-S00895413002006122100000) , in order to determine the correct pin length to use.

Front End Play Check

Tools Required

1. J 8001 Dial Indicator Set
2. J 25025-B Guide Pin Set. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 28585 Snap Ring Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 647

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the bolt holes on the transmission case assembly (7). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Assemble the J 8001-3 onto the dial indicator holder. Index the J 8001-3 to the end of the turbine shaft (502).
3. Eliminate any slack by pressing down on the turbine shaft (502).
4. Using the J 28585 , apply upward pressure on the output carrier assembly to remove free play in the retainer ring. See «Special Tools»(ref-246429-S18893617282006122100000) .
5. Set the J 8001-3 to 0.
6. Pull up on the turbine shaft (502) while holding up the output carrier assembly with the J 28585 . See «Special Tools»(ref-246429-S18893617282006122100000) . The correct end play is between 0.102-0.559 mm (0.004-0.022 in).
7. Record this measurement for future reference.
8. Remove the tools.

Rear Unit End Play Check

Tools Required

1. J 8001 Dial Indicator Set
2. J 25025-B Dial Indicator Post and Guide Pin Set. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 648

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the case extension bolt holes on the transmission case assembly (7). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Push in the output shaft assembly (671) to remove any slack.
3. Assemble the J 8001-3 onto the dial indicator holder. Index the J 8001-3 to the end of the output shaft (671).
4. Set the J 8001-3 to 0.
5. Move the output shaft (671) in and out, noting the amount of end play. The correct end play is between 0.127-0.508 mm (0.005-0.020 in).
6. Record this measurement for future reference.
7. Remove the tools.

Tools Required

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

Scheme 649

1. Remove the overdrive carrier/forward clutch thrust bearing assembly (601). The bearing may be stuck to the overrun clutch housing assembly.
2. Using the J 38358-A , remove the forward clutch housing assembly (602). See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Remove the forward clutch housing thrust washer (612).

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

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

Scheme 650

Scheme 651

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

Scheme 652

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

J 36850 Transjel® Lubricant

Scheme 653

1. Inspect the transmission case for the following: Cracks Porosity Connected passages Scored bushing Excess gasket material left on any case surfaces
2. Inspect all threaded holes for damage. Use a Heli-Coil kit in order to repair damage to the threaded holes.
3. Air check all fluid passages. Refer to the hydraulic fluid flow diagrams and the fluid passage in «Fluid Passages»(ref-246429-S31055836192006122100000) .
4. Inspect the manual 2-1 band servo bore and the low and reverse band servo bore for the following: Porosity Burrs Damage
5. Inspect the intermediate clutch plate lugs for damage.
6. Inspect the retainer ring grooves for damage.
7. Inspect the case center support bolt hole for damage.
8. Inspect the oil cooler pipe fitting holes for damage.
9. Inspect the vent pipe for damage.
10. Inspect the lube oil orifice cup plug with seal (some models) for damage.
11. Inspect the low/reverse band anchor pins and intermediate band anchor pins for proper position and tightness.
12. Inspect the manual shaft bore for damage and porosity.
13. Clean all of the transmission case components using clean solvent.

J 41505 Output Shaft Seal Installer. See Special Tools .

Scheme 654

Scheme 655

1. Using the J 41505 , install a new output shaft seal (13). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Install the output shaft seal retainer ring (14).

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Scheme 660

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

1. J 28585 Snap Ring Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 36850 Transjel® Lubricant

Scheme 661

1. Refer to the rear unit end play measurement taken during disassembly. If the rear unit end play measurement is not within specifications, use the removed selective thrust washer (674) and the Output Shaft Selective Thrust Washer Specifications table in order to select the correct selective thrust washer. Refer to «End Play Specifications»(ref-246429-S13969353912006122100000) .
2. Install the output shaft selective thrust washer (674).
3. Retain the output shaft selective thrust washer (674) with J 36850 or equivalent.
4. Using J 28585 , install the low and reverse band (657). See «Special Tools»(ref-246429-S18893617282006122100000) .
5. Install the center support spacer (643) into the case so it rests on the shoulder at the bottom of the case splines. The center support spacer opening should be placed at the 9 o'clock position.

Scheme 662

Scheme 663

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

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

Output Carrier Pinion End Play Measurement

Using a feeler gage, measure the pinion washer wear.

Scheme 670

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

Reaction Carrier Pinion End Play

Using a feeler gage, measure the pinion washer wear.

Scheme 671

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

Tools Required

1. J 8001 Dial Indicator Set
2. J 25025-B Dial Indicator Post and Guide Pin Set. See «Special Tools»(ref-246429-S18893617282006122100000) .

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the case extension bolt holes on the transmission case (7). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Push the output shaft assembly (671) in to remove any slack.
3. Install the J 8001-3 on the dial indicator holder. Index the J 8001-3 to the end of the output shaft (671).
4. Set the J 8001-3 to 0.
5. Move the output shaft (671) in and out, noting the amount of end play. End Play Specification: The correct end play is 0.127-0.508 mm (0.005-0.020 in). If the end play is not correct, change the output shaft selective thrust washer (674). Refer to the «Output Shaft Selective Thrust Washer Specifications»(ref-246429-S18084439822006122100000) .
6. Remove the tools.

J 23093 Center Support Alignment Tool. See Special Tools .

Scheme 672

1. Using the J 23093 , locate the center support 2nd clutch fluid passage through the hole in the case bottom. See «Special Tools»(ref-246429-S18893617282006122100000) . Refer to «Fluid Passages»(ref-246429-S31055836192006122100000) , Case Fluid Passages illustration.
2. Push the J 23093 toward the low and reverse band servo bore, seating the center support splines against the case splines. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Install the new center support bolt (25). Tighten: Maintain pressure on J 23093 while tightening the new center support bolt to 43 N. See «Special Tools»(ref-246429-S18893617282006122100000) .m (32 lb ft).
4. Ensure that the center support bolt head is seated to the bottom of the case.
5. Install a new rear oil cooler pipe fitting seal (91) onto the rear oil cooler pipe fitting (90).
6. Install the rear oil cooler pipe fitting (90) into the transmission case. Tighten: Tighten the fitting to 35 N.m (26 lb ft).

Scheme 673

Scheme 674

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

Intermediate Clutch Piston Travel Check

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

Scheme 675

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

Direct Clutch Piston Travel Check

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 7057 Dial Indicator Plunger Extension. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 676

1. Attach the J 7057 (not visible in the illustration) to the J 8001-3 . See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Using the J 8001-1 , mount the J 8001-3 to the transmission case through the opening in the case barrel. Place the J 7057 onto the direct clutch piston assembly. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Index the J 8001-3 . Set the dial to 0.
4. Apply 80 psi of air pressure to the direct clutch fluid passage (3rd/Reverse), in the case bottom, in order to actuate the direct clutch piston. Refer to «Fluid Passages»(ref-246429-S31055836192006122100000) , Case Fluid Passages illustration.
5. Measure the direct clutch piston travel. Piston Travel Specification: The piston travel should be 1.27-4.369 mm (0.050-0.172 in).
6. Remove the tools.

Forward Clutch Piston Travel Check

Tools Required

1. J 8001 Dial Indicator Set
2. J 26900-13 Magnetic Indicator Base

Scheme 677

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

J 36850 Transjel® Lubricant

Scheme 678

Scheme 679

Scheme 680

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

Fourth Clutch Piston Travel Check

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

Scheme 681

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

Scheme 682

Scheme 683

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

Overrun Clutch Piston Travel Check

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

Scheme 684

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

Overdrive Carrier Pinion End Play Check

Using a feeler gage, measure the pinion washer wear.

Scheme 685

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

Scheme 686

Scheme 687

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

J 36850 Transjel® Lubricant

Scheme 688

Scheme 689

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

Scheme 690

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

J 36850 Transjel® Lubricant

Scheme 691

Scheme 692

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

Scheme 693

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

Scheme 694

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

Scheme 695

Scheme 696

Scheme 697

Scheme 698

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

Scheme 699

Scheme 700

Scheme 701

Scheme 702

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

Scheme 703

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

Scheme 704

Scheme 705

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

Transmission Oil Pump Body Flatness Check

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

Scheme 706

J 38693 Oil Pump Seal Installer. See Special Tools .

Scheme 707

1. Using the J 38693 , install the torque converter oil seal assembly (201). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Lubricate the oil pump drive gear (205) and driven gear (204) with DEXRON®VI automatic transmission fluid.
3. Install the oil pump driven gear (204) and drive gear (205) with the identification dots facing up.

J 25025-1 Guide Pins

Scheme 708

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

Tools Required

1. J 8001 Dial Indicator Set
2. J 25025-B Dial Indicator Post and Guide Pin Set. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 28585 Snap Ring Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .

1. Assemble the J 25025-B by attaching the threaded rod and the dial indicator holder to one of the bolt holes on the transmission case assembly (7). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Assemble the J 8001-3 onto the dial indicator holder. Index the J 8001-3 to the end of the turbine shaft (502).
3. Eliminate any slack by pressing down on the turbine shaft (502).
4. Using J 28585 , apply upward pressure on the output carrier assembly to remove free play in the retainer ring. See «Special Tools»(ref-246429-S18893617282006122100000) .
5. Set the J 8001-3 to 0.
6. Pull up on the turbine shaft (502) while holding up the output carrier assembly with the J 28585 . See «Special Tools»(ref-246429-S18893617282006122100000) . End Play Specification: The correct end play is 0.102-0.559 mm (0.004-0.022 in).
7. Remove the tools from the transmission.
8. If the front end play measurement is incorrect, refer to the «Overrun Clutch Housing Selective Thrust Washer Specifications»(ref-246429-S13384575182006122100000) . Choose a new selective thrust washer based on the original selective washer and the information contained in the table.
9. Correct the end play by changing the overrun clutch housing selective thrust washer.

Scheme 709

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

Scheme 710

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

Scheme 711

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

Low and Reverse Band Servo Apply Piston Pin Check

Tools Required

1. J 21370-10 Band Apply Pin Gauge. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 38737 Band Apply Pin Checking Tool. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 712

1. Install the J 21370-10 into the low and reverse band servo pin bore. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Position the J 38737 over the low and reverse band servo bore with the hex hub facing the parking pawl linkage. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Fasten the J 38737 to the case with 2 low and reverse band servo cover bolts (61). See «Special Tools»(ref-246429-S18893617282006122100000) . Tighten: Tighten the bolts to 24 N.m (18 lb ft).
4. Verify that the J 21370-10 moves freely in the J 38737 and in the low and reverse band servo pin bore. See «Special Tools»(ref-246429-S18893617282006122100000) .
5. Tighten the hex hub of the J 38737 . See «Special Tools»(ref-246429-S18893617282006122100000) . Tighten: Tighten the hex hub of the J 38737 to 34 N. See «Special Tools»(ref-246429-S18893617282006122100000) .m (25 lb ft).
6. Observe the lands on the J 21370-10 in order to determine which land is even with the top edge of the J 38737 . See «Special Tools»(ref-246429-S18893617282006122100000) . Note the letter (A, B or C) stamped on the J 21370-10 . See «Special Tools»(ref-246429-S18893617282006122100000) .
7. Refer to the Low and Reverse Band Servo Piston Pin Specification chart, in the «Transmission General Specifications»(ref-246429-S00895413002006122100000) , in order to determine the correct pin length to use.
8. Remove the tools.

Scheme 713

Scheme 714

Scheme 715

Scheme 716

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

Scheme 717

Scheme 718

Scheme 719

Scheme 720

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

Scheme 721

Scheme 722

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

Scheme 723

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

Scheme 724

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

Scheme 725

Scheme 726

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

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

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

J 25025-5 Dial Indicator Mounting Post - M6 x 1.00

Scheme 736

Scheme 737

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

J 21366 Converter Holding Strap

Scheme 738

Scheme 739

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

Park or Neutral - Engine Running

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

Scheme 740

Reverse

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

Scheme 741

Overdrive Range, First Gear

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

Scheme 742

Overdrive Range, Second Gear

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

Scheme 743

Overdrive Range, 4-3 Downshift

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

Scheme 744

Overdrive Range, 3-2 Downshift

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

Scheme 745

Manual Third Gear

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

Scheme 746

Manual Second Gear

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

Scheme 747

Manual First Gear

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

Scheme 748

Scheme 749

Callouts For see scheme 286

Scheme 750

Callouts For see scheme 287

Scheme 751

Callouts For see scheme 288

Scheme 752

Callouts For see scheme 289

Scheme 753

Callouts For see scheme 290

Scheme 754

Callouts For see scheme 291

Scheme 755

Callouts For see scheme 292

Scheme 756

Callouts For see scheme 293

Scheme 757

Callouts For see scheme 294