Automatic Transaxle - 4T65-E - Overhaul: Diagnosis Chevrolet Uplander I

Inspection Procedure

1. Inspect the oil pan magnet (26) for steel particles. Excessive amounts of steel shavings indicate internal transmission damage.
2. Use a screwdriver or side cutters in order to open the oil filter assembly (100), by cutting or prying the metal crimping away from the top of the filter and by pulling the filter apart.
3. Inspect the filter (100) for excessive amounts of the following: Clutch plate assembly fiber material, indicating clutch distress Bronze slivers, indicating bushing wear Steel particles, indicating internal transmission damage

1. Inspect the components that are still on the transmission case for the following conditions: Loose, cross-threaded or damaged pipe fittings on the transmission oil cooler A loose, missing or damaged transmission name plate
2. Inspect the transmission case for the following conditions: Gasket sealing surfaces that are damaged or which have porosity Bolt or screw holes that are stripped or damaged (repair with a thread insert) Damaged or porous case oil passages Damaged snap ring grooves or housing splines Loose, missing or damaged band anchor pins Damaged or porous case surfaces Plugged drain back holes for the torque converter oil seal
3. Inspect the components that are still on the transmission case for the following conditions: A loose, plugged or damaged transmission vent assembly A loose, cross-threaded or damaged oil pressure test hole plug

1. Inspect the differential carrier assembly (700) for the following conditions: Damaged or worn teeth, bearing rollers, washers or pins on the differential planetary pinion gear Damaged or worn teeth or splines on the final drive sun gear (697) Damaged or worn teeth, splines or thrust washers on the differential side gear Damaged or worn teeth, thrust washers or shaft on the differential pinion gear Damaged or worn lugs or splines on the parking gear (696) A damaged vehicle speed sensor reluctor wheel Damaged internal gear/parking gear thrust bearing (695), differential carrier/sun gear thrust bearing (698) or differential carrier/case thrust bearing (715) A damaged or worn differential carrier/case selective thrust washer (714) A damaged differential/final drive carrier housing (700)
2. Inspect the final drive sun gear shaft (689) for the following conditions: Damaged or worn splines Cracks at lube oil holes Damaged or worn bearing journals
3. Use a feeler gauge in order to measure the end play of the differential carrier planetary pinion gear. Specification: End play should be 0.24-0.63 mm (0.009-0.025 in).
4. If the end play check or the component inspection indicates a condition, repair the differential/final drive carrier assembly (700).

1. Inspect the input clutch housing assembly (632) for the following: Plugged feed passages Worn or damaged splines Input shaft bushing (631) wear Seal ring groove nicks or burrs Cracks or blocked fluid passages in the input shaft Damage or wear to the thrust bearing (723) in the input clutch housing
2. With the ball check valve assembly in its seated position in transmission fluid, inspect the assembly for leaks.
3. Inspect the input clutch piston (636) for the following: Cracks or damage to seal grooves Wear on piston lugs
4. Inspect the input clutch spring and retainer assembly (637) for a damaged cage and distorted or missing springs.
5. Inspect the third clutch piston housing (639) for damage.
6. Inspect the third clutch spring retainer and guide assembly (643) for a damaged cage and distorted or missing springs.
7. Replace the third clutch piston and seal assembly (642).
8. Inspect the input shaft thrust bearing assembly (644) for damage or wear.

Scheme 94

Use a 6.25 mm (1/4 in) drift and mallet in order to remove the ball check valve assembly (633) from the input clutch housing.

Scheme 95

Use a 9.5 mm (3/8 in) drift punch and mallet in order to assemble a new ball check valve assembly (633) into the input clutch housing.

1. Inspect the second clutch housing assembly (617) for the following: A leaking or damaged ball check valve in the second clutch housing. Turn the housing in order to seat the check ball. Use transmission fluid in order to check for leaks. Scored or worn bushings Discolored band surface or wear on the drum caused by excess heat Flatness of the band surface on the drum Damaged reverse reaction drum splines Cracks in welds
2. Inspect the backing plate (626) and the waved plate (623) of the second clutch for cracks or heat spots.
3. Inspect the steel plates (625) and the apply plate (716) of the second clutch for wear.
4. Inspect the fiber plates (624) of the second clutch for wear, flaking or lining separation.
5. Inspect the spring assembly (621) of the second clutch for damage to the ring cage. Check for distorted or missing springs.
6. Inspect the spring snap ring (622) of the second clutch for damage. Inspect the snap ring (627) of the second clutch backing plate for damage.

Scheme 96

Use a 6.25 mm (1/4 in) drift and a mallet in order to remove the ball check valve assembly (618) from the second clutch housing (617).

Scheme 97

Use a 6.25 mm (1/4 in) drift and a mallet in order to remove the ball check valve assembly (618) from the second clutch housing (617).

1. Inspect the driven sprocket support assembly (609) for the following: Worn or cut oil seal rings (612) Rolled or cut second clutch housing oil seal ring seals (613) Damage to the piston seal surface in the driven sprocket support assembly Blocked or porous oil passages in the driven sprocket support assembly A leaking or missing cup plug
2. Inspect the fourth clutch piston (603) for damage.
3. Inspect the thrust washer (611) from the second clutch housing for cracks or distortion.
4. Inspect the fourth clutch spring assembly (602) for distorted or missing springs.
5. Inspect the driven sprocket bearing assembly for foreign material and missing, flat or damaged rollers.
6. Replace the Teflon® seal rings (613) under the following conditions: The rings are cut or damaged You are performing a complete overhaul
7. Inspect all seal ring grooves for debris, burrs or damage.

1. Inspect the 3-4 accumulator piston (428) for the following conditions: Porosity A scored pin bore A nicked piston seal groove
2. Inspect the 3-4 accumulator piston pin (426) for scoring and free movement in the 3-4 accumulator piston bore.
3. Inspect the 3-4 accumulator outer spring (423) and inner spring (424) for distorted or broken coils.
4. Inspect the 3-4 accumulator piston cylinder (421) for the following conditions: Porosity or cracks A rough or scored seal surface A cut seal (422)
5. Inspect the low blow off ball valve (420A), the low blow off ball valve spring (406) and the low blow off ball valve bore plug (405).
6. Inspect the TCC blow off ball valve (420B), the TCC blow off ball valve spring (418) and the TCC blow off ball valve bore plug (417).
7. Inspect the manual valve (404), the manual valve link (402) and the manual valve clip (403) for damage.
8. Inspect the manual valve (404) for binding or looseness in the case cover assembly (401).
9. Inspect the case cover bore plugs (411) and the orificed cup plug (412). Correct the following conditions: Plug is loose Plug is missing Orifice is plugged
10. Inspect the drive shaft bearing assembly (431).
11. Inspect the axle oil seal assembly (409) for a missing garter spring or for a cut lip seal.
12. Inspect the case cover (401) for the following: Porosity Interconnected fluid passages Cracks or rough machined surfaces
13. Inspect the input speed sensor assembly (440) for the following conditions: Damaged or missing magnet Damaged housing Bent or missing electrical terminals Damaged input speed sensor clip (441)

1. Inspect the 3-4 accumulator piston (428) for the following conditions: Porosity A scored pin bore A nicked piston seal groove
2. Inspect the 3-4 accumulator piston pin (426) for scoring and free movement in the 3-4 accumulator piston bore.
3. Inspect the 3-4 accumulator outer spring (423) and inner spring (424) for distorted or broken coils.
4. Inspect the 3-4 accumulator piston cylinder (421) for the following conditions: Porosity or cracks A rough or scored seal surface A cut seal (422)
5. Inspect the low regulator valve spring (422), the low regulator valve (443) and the low regulator valve bore plug (444).
6. Inspect the TCC blow off ball valve (420B), the TCC blow off ball valve spring (418) and the TCC blow off ball valve bore plug (417).
7. Inspect the manual valve (404), the manual valve link (402) and the manual valve clip (403) for damage.
8. Inspect the manual valve (404) for binding or looseness in the case cover assembly (401).
9. Inspect the case cover bore plugs (411) and the orificed cup plug (412). Correct the following conditions: Plug is loose Plug is missing Orifice is plugged
10. Inspect the drive shaft bearing assembly (431).
11. Inspect the axle oil seal assembly (409) for a missing garter spring or for a cut lip seal.
12. Inspect the case cover (401) for the following: Porosity Interconnected fluid passages Cracks or rough machined surfaces
13. Inspect the input speed sensor assembly (440) for the following conditions: Damaged or missing magnet Damaged housing Bent or missing electrical terminals Damaged input speed sensor clip (441)

1. Inspect the control valve body (301) for the following conditions: Worn or damaged oil pump drive shaft bearing journal (not serviceable separately from the control valve body) Damaged or porous casting Damaged sealing surfaces Debris in fluid passages
2. Use a small pick or screwdriver. Before disassembly, inspect the control valve body (301) components for the following conditions: Valves binding or sticking in their bores or bushings Broken, missing or damaged springs Missing or damaged retainers Damaged solenoid valves Debris in valve line-ups or solenoid valves
3. During disassembly, inspect the control valve body for the following conditions: Worn or damaged valves, valve bores or bushings Broken, missing or damaged springs Missing or damaged retainers Damaged solenoid valves Debris in valve line-ups or solenoid valves
4. Inspect the transmission fluid pressure (TFP) manual valve position switch assembly (395) for the following conditions: Damaged electrical connector terminals Damaged seals Damaged switch membranes Debris on the switch membranes

1. Position the torque converter (1) on the bench with the flywheel lugs facing down.
2. Install J 26900-13 , J 35138 and J 8001 onto the torque converter (1).
3. Set the dial indicator to 0.
4. Lift J 35138 and note the dial indicator reading: The torque converter end play should be 0.5 mm (0.020 in) or less If the end play is too high, replace the torque converter (1)
5. Inspect and replace the torque converter (1) for the following conditions: Overheated (torque converter will be blue in color) Leaking at the weld areas A damaged torque converter pilot Evidence of metal particles in the converter, the oil cooler or the cooler pipes A damaged torque converter stator, a damaged pump or a damaged turbine A damaged or worn torque converter bushing (2) Contaminated automatic transmission fluid due to engine coolant
6. Inspect the torque converter for stripped bolt hole threads. If found, repair the torque converter.