Automatic Transmission - 4L80-E/4L85-E - Overhaul: Removal & Installation Chevrolet Silverado 1500

Transmission Holding Fixture Installation

Tools Required

1. J 3289-20 Holding Fixture Base Assembly
2. J 8763-02 Holding Fixture. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 38655 Holding Fixture Adapter. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 530

1. Install the J 8763-02 and the J 38655 onto the transmission assembly. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Install the transmission assembly and the J 8763-02 into the J 3289-20 . See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Lock the J 8763-02 in place with the locking pin. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 531

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

Scheme 532

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

Case Extension Assembly Removal

Tools Required

1. J 23129 Universal Seal Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 6125-1B Slide Hammer. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 533

Scheme 534

1. Using the J 23129 and the J 6125-1B , remove the prop shaft front slip yoke seal assembly (20) (model dependent). See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Remove the case extension bolts (21).
3. Remove the case extension assembly (19).
4. Remove the case extension seal (15).
5. Remove the following components and inspect for damage and wear: The output shaft seal (675) (for some models) The transmission output shaft yoke seal sleeve (682) and output shaft seal (683) (for some models) The bearing retainer ring (16), case extension ball bearing assembly (17), and bearing spacer (18) (for some models)

Scheme 535

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

Scheme 536

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

Scheme 537

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

Scheme 538

Scheme 539

Scheme 540

Scheme 541

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

Scheme 542

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

Scheme 543

Scheme 544

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

Manual Shift Shaft Removal

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

Scheme 545

Scheme 546

Scheme 547

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

Transmission Oil Pump Assembly Removal

Tools Required

1. J 23129 Universal Seal Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 6125-1B Slide Hammer. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 45053 Universal Clamp Press. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 548

Scheme 549

Scheme 550

Scheme 551

1. Remove the turbine shaft front oil seal ring (2).
2. Using the J 23129 and the J 6125-1B , remove the torque converter oil seal assembly (201). See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Remove the 7 oil pump bolt and seal assemblies (3).
4. Attach the J 45053 to the oil pump shaft. See «Special Tools»(ref-246429-S18893617282006122100000) . Tighten the bolts.
5. Turn the handle of the J 45053 down onto the turbine shaft in order to raise the oil pump assembly (4) out of the case. See «Special Tools»(ref-246429-S18893617282006122100000) .
6. Remove the oil pump assembly (4).
7. Remove the J 45053 . See «Special Tools»(ref-246429-S18893617282006122100000) .
8. Remove the transmission oil pump gasket (6).
9. Remove the selective thrust washer (218).

Overdrive Assembly Removal

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

Scheme 552

Fourth Clutch Assembly Removal

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

Center Support and Gear Unit Assembly Removal

Tools Required

1. J 6116-A Rear Gear Holding Fixture. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 6129 Handle. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 21364-A Rear Gear Holding Fixture Adapter. See «Special Tools»(ref-246429-S18893617282006122100000) .
4. J 38868 Output Shaft Assembly Remover and Installer. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 553

Scheme 554

Scheme 555

Scheme 556

1. Remove the center support bolt (25).
2. Remove the rear oil cooler pipe fitting (90).
3. Inspect the rear oil cooler pipe fitting (90) for damaged threads.
4. Inspect the rear oil cooler pipe fitting seal (91) for nicks or cuts.
5. Remove the center support retainer ring (633).
6. Attach the J 38868 to the transmission main shaft. See «Special Tools»(ref-246429-S18893617282006122100000) .
7. Tighten the thumb screw on the J 38868 . See «Special Tools»(ref-246429-S18893617282006122100000) .
8. Install the J 6129 to the J 38868 . See «Special Tools»(ref-246429-S18893617282006122100000) .
9. Turn the J 6129 so that the handle shaft contacts the transmission main shaft. See «Special Tools»(ref-246429-S18893617282006122100000) .
10. Remove the center support and gear unit assembly (640-672) by lifting the J 38868 with the J 6129 . See «Special Tools»(ref-246429-S18893617282006122100000) .
11. Remove the J 6129 and the J 38868 . See «Special Tools»(ref-246429-S18893617282006122100000) .
12. Place the center support and gear unit assembly (640-672) into the J 21364-A (not visible in the illustration) and then into the J 6116-A . See «Special Tools»(ref-246429-S18893617282006122100000) .

Low and Reverse Band Removal

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

Output Shaft Seal Removal

Tools Required

1. J 6125-1B Slide Hammer. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 23129 Universal Seal Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 557

Scheme 558

1. Remove the output shaft seal retainer ring (14).
2. Inspect the output shaft seal retainer ring (14) for damage.
3. Using the J 23129 and the J 6125-1B , remove the output shaft seal (13). See «Special Tools»(ref-246429-S18893617282006122100000) .

Center Support and Gear Unit Assembly Installation

Tools Required

1. J 6129 Handle. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 28585 Snap Ring Remover. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 38868 Output Shaft Assembly Remover and Installer. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 559

1. Attach the J 38868 and the J 6129 onto the main shaft. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Align the bolt hole in the center support with the bolt hole in the case and carefully lower the center support and gear unit assembly (640-672) into the case.
3. Remove the tools.
4. Using the J 28585 , install the center support retaining ring (633). See «Special Tools»(ref-246429-S18893617282006122100000) . The end gap of the center support retaining ring (633) should be located at the 9 o'clock position with the beveled edge of the retaining ring facing up.

Manual 2-1 Band Assembly Installation

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

Scheme 560

Direct Clutch Assembly Installation

Tools Required

1. J 24396 Intermediate Clutch Pack Alignment Tool. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. J 38733 Direct Clutch Assembly Remover/Installer. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 561

Scheme 562

1. Using the J 24396 , align the intermediate clutch plates. See «Special Tools»(ref-246429-S18893617282006122100000) .
2. Apply compressed air through the center support bolt hole to apply the intermediate clutch. Continue applying compressed air to hold the intermediate clutch plates in place until the direct clutch assembly is installed.
3. Remove the J 24396 . See «Special Tools»(ref-246429-S18893617282006122100000) .
4. Using the J 38733 , install the direct clutch housing assembly (623) into the transmission case. See «Special Tools»(ref-246429-S18893617282006122100000) . Rotate the direct clutch housing assembly slightly in each direction to ease installation.
5. Remove the J 38733 . See «Special Tools»(ref-246429-S18893617282006122100000) .

Forward Clutch Assembly Installation

Tools Required

1. J 36850 Transjel® Lubricant
2. J 38358-A Forward Clutch Assembly Remover/Installer. See «Special Tools»(ref-246429-S18893617282006122100000) .

1. Align the direct clutch plates in order to aid in the installation of the forward clutch housing assembly (602).
2. Using the J 38358-A , install the forward clutch housing assembly (602). See «Special Tools»(ref-246429-S18893617282006122100000) .
3. Install the overdrive carrier/forward clutch thrust bearing assembly (601) (silver side up) onto the forward clutch housing assembly (602). Retain with J 36850 or equivalent.

Control Valve Body Assembly Installation

Tools Required

1. J 25025-5 Dial Indicator Mounting Post - M6 x 1.00
2. J 36850 Transjel® Lubricant

Scheme 563

Scheme 564

Scheme 565

Scheme 566

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

Scheme 567

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

Scheme 568

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

Transmission Fluid Pan Installation

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

Scheme 569

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

Case Extension Assembly Installation

Tools Required

1. J 36850 Transjel® Lubricant
2. J 38694 Extension Housing Seal Installer. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 38869 Rear Extension Seal Installer. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 570

Scheme 571

1. Install the prop shaft front slip yoke oil seal assembly (20) (model dependent) with the J 38869 or the J 38694 (for fixed yoke applications). See «Special Tools»(ref-246429-S18893617282006122100000) . Apply J 36850 or equivalent to the spring pocket of the seal.
2. Install the transmission output shaft yoke seal sleeve (682) and the output shaft seal (683) (for some models).
3. Install the output shaft seal (675) (for some models).
4. Install the bearing spacer (18), case extension ball bearing assembly (17) and the bearing retainer ring (16) (for some models).
5. Install the case extension seal (15) onto the case extension assembly (19).
6. Install the case extension assembly (19) onto the transmission case.
7. Install the case extension bolts (21). Tighten: Tighten the bolts to 34 N.m (25 lb ft).

Holding Fixture Removal

Tools Required

1. J 3289-20 Holding Fixture Base Assembly
2. J 8763-02 Transmission Holding Fixture. See «Special Tools»(ref-246429-S18893617282006122100000) .
3. J 38655 Holding Fixture Adapter. See «Special Tools»(ref-246429-S18893617282006122100000) .

Scheme 572

1. Remove the transmission assembly and the J 8763-02 from the J 3289-20 .
2. Remove the J 8763-02 and the J 38655 . See «Special Tools»(ref-246429-S18893617282006122100000) .