Automatic Transmission - 4L60-E/4L65-E - Overhaul & Testing: Other Chevrolet Tahoe II

GEAR RATIOS

TRANSMISSION GEAR RATIOS

CONVERTER HOUSING

Mount transmission on bench using Holding Fixture (J-8763-02). Remove torque converter. Using 50 mm Torx Plus Bit (J-41510), remove converter housing bolts, and remove converter housing. (Scheme 266)

Removing Torque Converter. Scheme 266

EXTENSION HOUSING

Remove Vehicle Speed Sensor (VSS) retaining bolt. Remove speed sensor assembly and "O" ring. (Scheme 286) Remove extension housing and seal. Remove output shaft sleeve and "O" ring (if equipped). Remove speed sensor rotor from output shaft (if necessary). Install Gear Puller (J-21427-01) and Adapter (J-8433) on rotor. Pull rotor from output shaft. Install Output Shaft Support Fixture (J-29837-A) on output shaft. (Scheme 267)

Scheme 267

VALVE BODY, 1-2 & 3-4 ACCUMULATORS

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

Scheme 274

Scheme 275

Scheme 276

Scheme 277

1. Remove transmission oil pan. Remove oil filter and "O" ring. Ensure "O" ring is removed from transmission case. Remove electrical connectors from switches and solenoids, and mark for reassembly reference. (Scheme 268)Remove TCC PWM solenoid retainer clip. Remove solenoid. (Scheme 269)
2. Remove TCC solenoid bolts. (Scheme 270) Remove valve body bolts securing wiring harness. Remove TCC solenoid and allow wiring harness to hang over side of case. (Scheme 271) Remove transmission fluid pressure manual valve position switch. (Scheme 272) Remove detent spring bolt. Remove detent spring. (Scheme 273) Remove remaining valve body bolts. Note length and location of bolts for installation reference. (Scheme 274)
3. Note direction of manual valve link. Remove manual valve link from manual valve at valve body. (Scheme 275) Remove valve body. Note location of check balls on valve body. (Scheme 276)
4. Carefully remove accumulator cover retaining bolts, 1-2 accumulator cover and pin assembly. (Scheme 287) Remove 1-2 accumulator piston, seal and spring. Remove spacer plate beside 1-2 accumulator. Note check ball and filter locations. (Scheme 277) Remove spacer plates. Remove spring, 3-4 accumulator piston and pin. (Scheme 268): Locating Valve Body Solenoids (Scheme 269): Removing TCC PWM Solenoid (Scheme 270): Removing TCC Bolts (Scheme 271): Removing TCC Solenoid & Wire Harness (Scheme 272): Removing Transmission Fluid Pressure Assembly (Scheme 273): Removing Detent Spring Assembly (Scheme 274): Identifying Valve Body Bolt Location

OIL PUMP, INPUT CLUTCH & REVERSE CLUTCH

1. Ensure TCC solenoid assembly and oil filter are removed before oil pump removal. Remove turbine shaft "O" ring. Remove oil pump retaining bolts. Using Oil Pump Remover (J-37789-A) and Adapter (J-39119), pull oil pump assembly free from case. (Scheme 278)
2. Remove oil pump, seal and gasket. Remove reverse input clutch-to-pump thrust washer from pump. Remove band anchor pin from case. (Scheme 285)Lift out input housing, shaft assembly, reverse input clutch housing and drum assembly. (Scheme 279)

Scheme 278

Removing/Installing Input Clutch Assembly. Scheme 279

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

1. Remove 2-4 band assembly from case. (Scheme 280) Remove input sun gear. (Scheme 288)
2. Remove input carrier-to-output shaft retainer ring. (Scheme 281) Remove input carrier (planetary). Remove input carrier thrust bearing from reaction carrier shaft. (Scheme 282)
3. Remove input internal gear and reaction carrier shaft assembly. (Scheme 283) Remove reaction sun shell and thrust washer. (Scheme 284) Remove reaction sun gear, thrust washer, low-reverse roller clutch race and roller clutch. (Scheme 288)

Removing/Installing 2-4 Band Assembly. Scheme 280

Removing/Installing Input Carrier To Output Shaft Retainer. Scheme 281

Removing/Installing Input Carrier Assembly. Scheme 282

Removing/Installing Input Internal Gear & Reaction Carrier Shaft Assembly. Scheme 283

Removing Thrust Washer & Reaction Sun Shell. Scheme 284

Scheme 285

Scheme 286

Scheme 287

Scheme 288

LOW-REVERSE CLUTCH

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

1. Remove low-reverse support-to-case retaining snap ring. Remove output shaft support fixture. (Scheme 267) Push up on output shaft to loosen low-reverse clutch support. Remove support retainer spring from low-reverse support. Remove low-reverse support assembly and reaction carrier assembly (planetary). (Scheme 288) Remove output shaft.
2. Remove low-reverse clutch plates. Note locations of components. (Scheme 289) Remove internal reaction gear and thrust bearing. Remove internal reaction gear support-to-case thrust bearing. (Scheme 290)
3. Remove parking lock bracket retaining bolts. Remove lock bracket. Using screw extractor, remove shaft plug. Remove parking pawl shaft, parking pawl and return spring if necessary. (Scheme 292)
4. Using Clutch Spring Compressor (J-23327), compress low reverse clutch spring retainer. Remove spring retaining ring and low-reverse spring assembly. Remove low-reverse clutch piston by applying air pressure in case apply passage. (Scheme 291)

Scheme 289

Removing/Installing Internal Reaction Gear & Thrust Bearing. Scheme 290

Scheme 291

INNER MANUAL SHAFT LINKAGE

Remove manual shaft nut. Remove manual shaft and retainer. Remove parking lock actuator assembly and inner detent lever. Remove manual shaft seal from transmission case. (Scheme 292)

Scheme 292

LOW-REVERSE SUPPORT

VALVE BODY

1. Place transmission in a vertical position. Install seals on low-reverse clutch piston. Apply petroleum jelly to seals. Align and install piston with notch in bottom of transmission case (695). Ensure piston is fully seated and parking pawl aligns with opening in piston wall. (Scheme 293) Install the low and reverse clutch spring assembly (694). Using the Clutch Spring Compressor (J23327-1), compress the low and reverse clutch spring assembly (694). Using the Snap Ring Remover and Installer (J36850), install the low and reverse clutch retainer ring (693). (Scheme 294)
2. Coat bearing assembly with petroleum jelly. Install bearing assembly on case hub with outside bearing race toward case hub. Install internal reaction gear and support. Install bearing assembly onto support with outside bearing race toward support. Install oil deflector (if equipped) and reaction carrier assembly in case. (Scheme 288)
3. Place waved plate on work bench. Install 5 composition plates and 4 steel plates alternately, starting with composition plate. Install low-reverse support. Apply light pressure to low-reverse support. Do not flatten waved plate. Measure height of clutch pack from work bench to top of low-reverse support. (Scheme 295)
4. Using height dimension, determine proper selective spacer plate to be used. See «SPACER PLATE SELECTION»(ref-156199-S29089093402003071000000) table. SPACER PLATE SELECTION Measured Clutch Pack Height - In. (mm) (1) Identification Plate Thickness - In. (mm) 1.084-1.105 (27.53-28.07) None.066-.072 (1.67-1.85) 1.105-1.125 (28.07-28.58) "0".046-.052 (1.17-1.31) 1.064-1.084 (27.03-27.53) "1".087-.092 (2.19-2.34) (1) Clutch pack height is measured without spacer plate in position.
5. Place spacer plate between waved plate and first composition plate with identification facing upward. Measure overall height of clutch pack. Overall height should be 1.15-1.18" (29.2-29.9 mm). Install low-reverse clutch pack into transmission case. Ensure clutch plates align with splines of reaction carrier. Ensure steel plates are properly indexed in transmission case. (Scheme 296)
6. Install low-reverse support in case with hub downward. Install inner race by pushing downward while rotating until it is fully engaged. Bottom tangs will be flush with hub when fully installed. Install spring retainer in case between case lug and open notch in support. Install low-reverse snap ring. (Scheme 297)

Scheme 293

Scheme 294

Scheme 295

Scheme 296

Scheme 297

REACTION & INPUT GEAR SETS

1. Install retainer ring on reaction sun gear (if removed). Install sun gear into reaction carrier. Install thrust washer on low-reverse clutch race. Install reaction sun gear shell on reaction sun gear.
2. Install thrust washer on reaction sun gear shell. Ensure thrust washer tangs engage on gear shell. Install input internal gear and reaction carrier shaft in sun gear shell. Carrier shaft splines must engage with reaction carrier. (Scheme 288)
3. Install thrust washer on reaction carrier shaft. Outer race must face toward reaction carrier shaft. Install output shaft in transmission. Ensure output shaft engages with all parts.
4. Install Output Shaft Support (J-29837-A). (Scheme 267) Adjust support so output shaft is positioned upward as far as possible. Install input carrier (planetary) assembly with hub end down on output shaft. Install NEW retainer ring on output shaft. Remove output shaft support. Install input sun gear, indexing gear end with input carrier pinions.

TRANSMISSION END PLAY CHECK

1. Install Pump Remover/End Play Fixture (J-24773-A) and End Play Adapter (J-25022-A) on end of turbine shaft. (Scheme 298) Clamp dial indicator on long bolt with indicator tip on end play fixture. Zero dial indicator.
2. Pull up on end play fixture. Measure transmission end play. Transmission end play should be.005-.036" (.13-.91 mm). If transmission end play is not within specification, selective thrust washer must be changed between oil pump and input housing. (Scheme 288) Install appropriate thrust washer, and recheck end play. See «OIL PUMP THRUST WASHER SPECIFICATIONS»(ref-156199-S16656892732003071000000) table.

OIL PUMP THRUST WASHER SPECIFICATIONS

Scheme 298

1. Install 3-4 accumulator piston pin in case. Install 3-4 piston seal on piston. Install 3-4 accumulator piston on pin. Legs of piston must face valve body.
2. Install 3-4 accumulator spring. Install oil screens in proper locations. (Scheme 299) (Scheme 277)for check ball and filter installation locations. Install alignment pins in transmission case to aid spacer plate and valve body installation. Install spacer plate gasket and spacer plate. Install spacer plate support.
3. Install 1-2 accumulator spring, oil seal ring and 1-2 accumulator piston. Install accumulator cover and bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000).
4. Coat check balls with petroleum jelly. Install check balls in proper locations in valve body. (Scheme 276)and (Scheme 277). Install manual valve link. Ensure manual valve link is properly seated in manual valve. (Scheme 275) Improper positioning may prevent vehicle operation in "D" range. NOTE: Improper positioning of throttle valve link will result in erratic shift points or high oil pressure.
5. Install valve body and retaining bolts. Ensure correct length and location of bolts. (Scheme 274) Install detent spring. Install detent spring bolt. Install transmission fluid pressure manual valve position switch. Install TCC solenoid. Install valve body bolts that secure wiring harness. Tighten all valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000).
6. Install TCC PWM solenoid. Install retainer clip. Install electrical connectors to switches and solenoids. (Scheme 268) Install oil filter and "O" ring. Install transmission oil pan.

Scheme 299

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

Scheme 300

Scheme 301