Automatic Transmission - 4L80-E/4L85-E (Overhaul): Removal & Installation Chevrolet Silverado 3500

Transmission Holding Fixture Installation

Tools Required

1. J 3289-20 Holding Fixture Base Assembly. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 8763-02 Holding Fixture. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
3. J 38655 Holding Fixture Adapter. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

1. Install the J 8763-02 and the J 38655 onto the transmission assembly.
2. Install the transmission assembly and the J 8763-02 into the J 3289-20 .
3. Lock the J 8763-02 in place with the locking pin.

Speed Sensor Assembly Removal

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 and Equipment»(ref-186420-S27067422292005083000000) .
2. J 6125-1B Slide Hammer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

1. Using the J 23129 and the J 6125-1B , remove the prop shaft front slip yoke seal assembly (20) (model dependent).
2. Remove the case extension bolts (21).
3. Remove the (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)

Transmission Oil Pan Removal

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).

Transmission Oil Filter Assembly Removal

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.

Transmission Wire Harness Removal

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.

Control Valve Body Assembly Removal

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).

Manual 2-1 Band Servo Assembly Removal

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.

Low and Reverse Band Servo Assembly Removal

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.

Parking System Components Removal

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 and Equipment»(ref-186420-S27067422292005083000000) .
2. J 6125-1B Slide Hammer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
3. J 45053 Universal Clamp Press. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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).
3. Remove the 7 oil pump bolt and seal assemblies (3).
4. Attach the J 45053 to the oil pump shaft. 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.
6. Remove the oil pump assembly (4).
7. Remove the J 45053 .
8. Remove the transmission oil pump gasket (6).
9. Remove the selective thrust washer (218).

Scheme 704

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

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.

Removal Procedure

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).
3. Remove the forward clutch housing thrust washer (612).

Manual 2-1 Band Assembly Removal

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

Intermediate Clutch Assembly Removal

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

Center Support and Gear Unit Assembly Removal

Tools Required

1. J 6116-A Rear Gear Holding Fixture. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 21364-A Rear Gear Holding Fixture Adapter. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
3. J 38868 Lower Gear Unit Assembly Remover/Installer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
4. J 6129 Handle. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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.
7. Tighten the thumb screw on the J 38868 .
8. Install the J 6129 to the J 38868 .
9. Turn the J 6129 so that the handle shaft contacts the transmission main shaft.
10. Remove the center support and gear unit assembly (640-672) by lifting the J 38868 with the J 6129 .
11. Remove the J 6129 and the J 38868 .
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 .

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 and Equipment»(ref-186420-S27067422292005083000000) .
2. J 23129 Universal Seal Remover. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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).

Installation Procedure

1. Using the J 41505 , install a new output shaft seal (13).
2. Install the output shaft seal retainer ring (14).

Parking System Components Installation

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. 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-186420-S03921519712005083000000) .
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).
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.

Center Support and Gear Unit Assembly Installation

Tools Required

1. J 38868 Lower Gear Unit Assembly Remover/Installer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 6129 Handle. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
3. J 28585 Snap Ring Remover. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

1. Attach the J 38868 and the J 6129 onto the main shaft.
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). 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.

1. Using the J 23093 , locate the center support 2nd clutch fluid passage through the hole in the case bottom. Refer to «Fluid Passages»(ref-186420-S37758647662005083000000) , 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.
3. Install the new center support bolt (25). Tighten: Maintain pressure on J 23093 while tightening the new center support bolt to 43 N.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).

Intermediate Clutch Assembly Installation

1. Dip all of the intermediate clutch plates in DEXRON® III 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.

Scheme 705

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

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

Scheme 706

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.

Direct Clutch Assembly Installation

Tools Required

1. J 24396 Intermediate Clutch Pack Alignment Tool. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 38733 Direct Clutch Assembly Remover/Installer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

1. Using the J 24396 , align the intermediate clutch plates.
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 .
4. Using the J 38733 , install the direct clutch housing assembly (623) into the transmission case. Rotate the direct clutch housing assembly slightly in each direction to ease installation.
5. Remove the J 38733 .

Forward Clutch Assembly Installation

Tools Required

1. J 38358-A Forward Clutch Assembly Remover/Installer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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).
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.

Fourth Clutch Assembly Installation

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).

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.

Fourth Clutch Plate Installation

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).

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).

Manual 2-1 Band Servo Assembly Installation

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 Assembly Installation

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.

Third and Fourth Clutch Accumulator Housing Removal

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).

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 .

Control Valve Body Assembly Installation

Tools Required

1. J 25025-5 Guide Pin. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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).

Wiring Harness Installation

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).

Transmission Oil Filter Assembly Installation

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 Oil 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).

Speed Sensor Assembly Installation

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 38694 Extension Housing Seal Installer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 38869 Rear Extension Seal Installer. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
3. J 36850 Assembly Lubricant. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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). 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).

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.

Holding Fixture Removal

Tools Required

1. J 3289-20 Holding Fixture Base Assembly. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
2. J 8763-02 Transmission Holding Fixture. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .
3. J 38655 Holding Fixture Adapter. See «Special Tools and Equipment»(ref-186420-S27067422292005083000000) .

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 .