Automatic Transaxle - 4T65-E - Overhaul: Overhaul — Chevrolet Uplander I (2004-2008)

Disassembly Procedure

Position the transaxle so that the control valve body cover (53) is facing up.
Remove the 17 control valve body cover bolts: 9 flanged bolts (56) 4 TORX bolts (57) 4 stud bolts (58)
Remove the cover (53), outer gasket (54) and inner gasket (59).

Inspect the vent for damage or being plugged. If the vent is damaged, use channel locks and a large screwdriver in order to remove the vent assembly (37).
Remove the oil pressure test hole plug (38).

Assembly Procedure

Use a hammer and a punch in order to install the vent assembly (37), if necessary.
Apply sealant GM P/N 12345382 to the oil pressure test hole plug (38).
Install the oil pressure test hole plug (38). Tighten: Tighten the oil pressure test hole plug (38) to 12 N.m (106 lb in).

Assemble J 28677 and J 8092 . See «Special Tools»(ref-246425-S06796853872006122100000) .
Lubricate drive sprocket support bearing (521) with J 36850 .
Using the assembled tool, press in the drive sprocket support bearing (521).
Install the drive sprocket support assembly (522).
Install the four drive sprocket support bolts (524). Tighten: Tighten the bolts to 25 N.m (18 lb ft).

Inspect the differential carrier internal gear assembly (693) for the following conditions: Damaged or worn bushings Plugged lube oil holes Damaged case splines Damaged or worn gear teeth A damaged or worn park pawl assembly (694) A damaged snap ring (692)
Install the differential carrier internal gear assembly (693) into the case. Align the park pawl assembly with the park pawl actuator assembly.
Use J 28585 or a long screwdriver in order to install the snap ring (692) into the case as shown.

Use a screwdriver in order to remove the snap ring (699) from the front differential carrier.
Remove the first planetary pinion by removing the following parts: The planetary pinion gear pin (712) The pinion thrust washers (708) The pinion gear roller bearings (709) The bearing roller spacer (710) The pinion (711)
Remove the remaining planetary pinions in the same way.
Remove the differential carrier sun gear thrust bearing assembly (698).
Place the final drive carrier components into an oil pan in order to make sure that none of the bearing rollers are lost.
Use a drift punch and a mallet in order to remove the differential pinion gear shaft pin (702).
Remove the differential pinion shaft (701).
Remove the differential pinion gears (704).
Remove the differential pinion gear thrust washers (703).
Remove the differential side gears (705).
Remove the differential side gear thrust washers (706).

Affix the differential side gear thrust washers (706) to the side gears (705). Apply J 36850 or equivalent.
Install the side gears (705) with the thrust washers into the differential carrier housing (700).
Affix the differential pinion thrust washers (703) to the pinion gears (704). Apply J 36850 or equivalent.
Install the pinion gears with thrust washers into the differential carrier housing (700). Rotate the pinion gears into position.
Install the differential pinion shaft (701) into the differential carrier housing.
Align the hole in the pinion gear shaft (701) to the hole in the differential carrier housing (700).
Use a drift punch and a mallet in order to install the pinion gear shaft pin (702) into the differential carrier housing (700).
Apply J 36850 or equivalent to the inside of a differential carrier planetary pinion gear (711).
For each planetary pinion gear, insert a bearing roller spacer (710) onto the pin (712). The spacer must be inserted between the two rows of bearing rollers.
For each planetary pinion gear, assemble the bearing rollers (709) into the gear (711) one at a time. Use plenty of J 36850 or equivalent in order to aid assembly Use a washer (708) on the bottom of the pinion gear (711) in order to help hold the bearing rollers (709) in place. The number of rollers in the pinion gear is model dependent: The 3.05/3.06 and 3.29/3.33 ratio differential carriers have two rows of 22 rollers (44 total) The 2.86/2.84 ratio differential carriers have two rows of 18 rollers (36 total) Occasionally twist the pinion gear pin (712) in order to help align the rollers
Install the differential carrier sun gear thrust bearing (698) into the carrier housing.
Remove each planetary pinion gear pin (712) from its pinion gear (711). Be careful not to move the rollers out of position.
Affix two pinion gear thrust washers (708) on each side of the pinion gear (711). Apply J 36850 or equivalent.
Install the pinion gear assemblies (711) into the carrier housing (700).
Install each planetary pinion gear pin (712).
Install the snap ring (699) over the planetary pinion gear pins.

Do not remove the vehicle speed sensor reluctor wheel (713) unless the wheel is damaged.
Use J 22888-D and a piece of flat metal stock in order to remove the vehicle speed sensor reluctor wheel (713). See «Special Tools»(ref-246425-S06796853872006122100000) .

Warm the vehicle speed sensor reluctor wheel before installation
Use a plastic mallet in order to install the vehicle speed sensor reluctor wheel (713) onto the differential carrier housing. Tap evenly around the reluctor wheel with the mallet until fully seated.

Assemble the final drive sun gear (697) with the chamfered side toward the parking gear (696) into the differential/final drive carrier assembly (700).
Assemble the parking gear (696) onto the final drive sun gear shaft (689)
Assemble the final drive sun gear shaft/parking gear assembly (689/696) into the final drive sun gear (697).
Assemble the internal gear/parking gear thrust bearing (695) to the parking gear (696).
Install the differential/final drive carrier assembly into the case.

Inspect the case extension assembly (6) for the following conditions: A damaged or porous sealing surface for the case extension seal A damaged or porous sealing surface for the vehicle speed sensor A damaged or porous sealing surface for the right drive shaft oil seal assembly Damaged bolt holes A worn or damaged front differential carrier bushing (7A) or output shaft bearing assembly (7B) A porous or damaged case extension housing
Install the differential carrier/case selective thrust washer (714) onto the differential/final drive carrier assembly (700).
Install the thrust bearing (715) onto the differential/final drive carrier assembly (700).
Affix the seal (8) onto the case extension (6).
Install the case extension assembly (6) onto the case (3).
Install only two case extension bolts (5) for later removal. Tighten: Tighten the bolts until the extension is flush to the case.
Perform end play check, refer to «Differential Carrier End Play Check (FWD Only)»(ref-246425-S10284782222006122100000) .

Inspect the forward band assembly (688) for the following conditions: Damaged or severely worn friction material Damaged apply or anchor pin features
Inspect the bearing (691) from the differential carrier internal gear for damage.
Position the transmission case so that the flange for the case cover is facing up.
Install the bearing (691) for the differential carrier internal gear into the case. Position as indicated.
Install the forward band assembly (688) into the case. Locate the band assembly onto the forward band anchor pin Position the band apply pin feature in the opening of the case

Use a small screwdriver in order to gently pry the thrust bearing (685) off of the 1-2 support drum (687).
Lift the 1-2 clutch roller assembly (683) out of the 1-2 support drum.

Inspect the 1-2 support roller clutch components for the following conditions: A scored or burned contact surface for the manual 2-1 band on the 1-2 support drum (687) A damaged or worn forward drum bushing A damaged or worn inner race of the 1-2 support roller clutch A damaged or worn 1-2 clutch roller assembly (683) A damaged thrust bearing (685)
Install the 1-2 clutch roller assembly (683) into the 1-2 support drum.
Install the thrust bearing (685) onto the 1-2 support drum (687). Press down with hand pressure only.

Inspect the 2-1 manual band (680) for the following: Cracked or separated friction material Burnt friction material Cracks around the apply lugs
Squeeze the manual 2-1 band assembly (680) and install the assembly into the case.
Position the band on the anchor pin.

Inspect the reaction sun gear and drum assembly (678) for the following: Worn or scored bushings Damaged reaction sun gear teeth The band apply area of the drum for discoloration or wear The welds connecting the sun gear to the drum for voids or cracks A worn or damaged 1-2 support outer race
Install the reaction sun gear and drum assembly (678) into the case.
Check that the lugs engage with the 1-2 support roller clutch inner race.

Inspect the thrust bearings (671, 674, 676) for the following: A damaged cage Damaged or missing rollers
Inspect the reaction carrier assembly (675) for the following: Damage to the pinion teeth Damage to the internal gear teeth
Inspect the input carrier assembly (672) for the following: Damage to the pinion teeth Damage to the spline teeth
Install the reaction carrier/sun gear thrust bearing (676) into the reaction carrier assembly (675). Use J 36850 or equivalent in order to retain the bearing.
Install the reaction carrier assembly (675) into the case and rotate the carrier so that the pinions engage the reaction sun gear.
Install the input/reaction carrier thrust bearing (674) into the input carrier assembly (672). Use J 36850 or equivalent in order to retain the bearing.
Install the input carrier/reaction carrier lube dam (673) into the input carrier assembly (672). Use J 36850 or equivalent in order to retain the lube dam.
Insert the input carrier assembly (672) into the case and rotate the carrier so that the pinions engage the reaction carrier internal gear.

Inspect the reverse reaction drum (669) for the following: Cracks Damaged splines Distortion
Install the reverse reaction drum (669) into the case and engage the drum onto the input carrier splines.

Scheme 101

Scheme 101: Input and Third Clutch Pawl Disassemble

IMPORTANT

The third and input clutch pawl assemblies (727, 728) are serviced as assemblies, do not disassemble.

Disassemble the third and input clutch pawl assemblies (727, 728) and input sungear shaft (668) from the input clutch housing assembly (632).

Inspect the input sun gear (668) for the following: Worn or damaged splines Plugged lube holes or cracks
Inspect the third and input clutches pawl for the following: Worn or damaged splines Wear or cracks
Install the input clutch pawl assembly (728) onto the input sun gear shaft (668).
Install the third clutch pawl assembly (727) onto the input sun gear (668).

Use a flat blade screwdriver in order to remove the retaining ring (659) from the input shaft and housing assembly (632).
Remove the input clutch backing plate (658).
Remove all of the input clutch plate assemblies (656, 657).
Remove the input clutch waved plate (655) and the input clutch apply plate (654).
Use a flat blade screwdriver in order to remove the retaining ring (649) from the input shaft and housing assembly (632).
Remove the third clutch backing plate (648)
Remove the third clutch plate assemblies (646, 647).
Remove the third clutch waved plate (645).
Remove the input shaft thrust bearing assembly (644).
Use J 23327 and J 25018-A in order to compress the third clutch spring retainer and guide assembly.
Use J 8059 in order to remove the retaining ring (640) from the input shaft and housing assembly. See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove J 23327 and J 25018-A from the input shaft and housing assembly.
Remove the third clutch retainer and guide spring assembly (643).
Remove the third clutch piston and seal assembly (642).
Use J 23327 in order to compress the input clutch spring and retainer assembly.
Use J 8059 in order to remove the retainer ring (640) from the input shaft and housing assembly. See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove J 23327 from the input shaft and housing assembly.
Remove the third clutch piston housing (639).
Remove the input clutch spring and retainer assembly (637).
Remove the input clutch piston assembly (636).
Remove the input clutch piston outer seal (635).
Remove the third clutch piston inner seal (641).
Remove the third clutch housing O-ring seal (638).
Remove the input clutch piston inner seal (634).
Cut the input shaft oil seal rings (628).
Remove the input shaft oil seal rings (628).

Use transmission fluid in order to lubricate the new input clutch piston inner seal (634).
Use J 37361 in order to install the new seal. See «Special Tools»(ref-246425-S06796853872006122100000) .
Insert a new third clutch housing O-ring seal (638) in the input shaft and housing assembly.
Use transmission fluid in order to lubricate the new third clutch piston inner seal (641).
Use J 37362 in order to install the seal in the input shaft and housing assembly (632). See «Special Tools»(ref-246425-S06796853872006122100000) .
Use transmission fluid in order to lubricate the new input clutch piston outer seal (635).
Insert the new seal onto the input clutch piston assembly (636).
Install the input clutch piston assembly (636) into the input shaft and housing assembly.
Install the input clutch spring and retainer assembly (637) into the input shaft and housing assembly.
Install the third clutch piston housing (639) into the input shaft and housing assembly.
Use J 23327 (1,2) and J 8059 (3) in order to install the third clutch piston housing retaining ring (640) in the input shaft and housing assembly. See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove the J 23327 (1,2).
Use transmission fluid in order to lubricate the new third clutch piston and seal assembly (642). Install the third clutch piston and seal assembly (642) into the input shaft and housing assembly (632).
Install the third clutch spring retainer and guide assembly (643) into the input shaft and housing assembly (632).
Use J 23327 (1,2), J 25018-A (4) and J 8059 (3) in order to install the third clutch spring retainer and guide assembly retaining ring (640). See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove the J 23327 (1,2).
Insert the third clutch waved plate (645) into the input shaft and housing assembly (632).
Insert the third clutch plates assemblies into the input housing. Start by inserting a third clutch plate (646) with external splines. Alternate with the internally splined clutch plates (647).
Insert the third clutch backing plate (648) with the word UP facing upward.
Insert the retaining ring (649) into the input shaft and housing assembly (632).
Insert the input clutch apply plate (654) into the input shaft and housing assembly (632), so that the notched side of the teeth are facing downward against the retaining ring on the third clutch backing plate.
Install the input clutch waved plate (655).
Install the input clutch plates (656/725, 657) starting with an input clutch steel plate (657) and alternating with input clutch fiber plate assemblies (656).
Insert the input clutch backing plate (658) with the tapered side of the teeth facing upward.
Insert the retaining ring (659) in the input shaft and housing assembly (632).
Insert the input shaft thrust bearing assembly (644).

Install J 34741-1 into the input clutch housing (632). See «Special Tools»(ref-246425-S06796853872006122100000) . Adjust J 34741-1 so that the bottom of the seal installer aligns with the lowest seal ring groove. See «Special Tools»(ref-246425-S06796853872006122100000) .
Use transmission fluid in order to lubricate the oil seal ring for the input clutch housing. Position the ring on the J 34741-1 . See «Special Tools»(ref-246425-S06796853872006122100000) .
Position J 34741-2 onto the J 34741-1 . See «Special Tools»(ref-246425-S06796853872006122100000) . Push the seal (628) into the seal ring groove.
Repeat this procedure for the second and the third seal rings (628).
Remove the input seal installer.
Use a twisting motion in order to assemble J 34741-3 over the seals. See «Special Tools»(ref-246425-S06796853872006122100000) .
Leave J 34741-3 in place until the input clutch housing assembly (632) is assembled into the transmission. See «Special Tools»(ref-246425-S06796853872006122100000) .

Use a small screwdriver in order to align the teeth of the input clutch plate assembly and the third clutch plate assembly. This will ease installation of the clutch pawl assembly.
Insert the combined input clutch pawl (728), third clutch pawl (727) and input sun gear (668) assembly into the input clutch housing assembly (632).

Use a flat blade screwdriver in order to remove the retaining ring (627) from the second clutch housing.
Remove the second clutch backing plate (626). Remove the alternating second clutch fiber plates (624). Remove the second clutch steel plates (625).
Remove the second clutch apply plate (716). Remove the second clutch waved plate (623).
Use J 23327 (1) and J 38734 (2) in order to compress the second clutch piston spring (621).
Remove the retaining ring (622).
Remove J 23327 and J 38734 from the second clutch housing (617).
Remove the second clutch spring assembly (621).
Remove the second clutch piston assembly (620).

Install J 41992-2 (1) into the second clutch housing (617). See «Special Tools»(ref-246425-S06796853872006122100000) .
Install the second clutch piston (620) and J 41992-3 (3) into J 41992-1 (2) protector. See «Special Tools»(ref-246425-S06796853872006122100000) .
Install the second clutch piston and tool assembly into the second clutch housing assembly (617).
Use hand pressure to press down on J 41992-3 (3) until the second clutch piston (620) is seated. See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove J 41992-1 (2), J 41992-2 (1) and J 41992-3 (3). See «Special Tools»(ref-246425-S06796853872006122100000) . If necessary, gently tap with a punch through the center of the second clutch housing to remove the tools.
Assemble the second clutch spring assembly (621) into the second clutch housing assembly (617).
Use J 23327 (1) and J 38734 (2) in order to compress the second clutch piston spring (621).
Install the second clutch spring assembly retainer ring (622).
Remove J 23327 and J 38734 from the second clutch housing (617).
Install the second clutch waved plate (623) into the second clutch housing (617).
Install the second clutch apply plate (716) into the second clutch housing (617) with the marking DN or DOWN toward the piston.
Install the second clutch fiber plate assemblies (624) and the second clutch steel plates (625), starting with a fiber plate assembly.
Assemble the remaining plates, alternating between steel and fiber.
Install the second clutch backing plate (626) into the housing.
Install the second clutch backing plate retaining ring (627).

Inspect the reverse band assembly (615) for the following: Cracks Scoring Lining separation Wear of the fiber material
Inspect the apply lug for cracks.
Install the reverse band assembly (615) into the case with the band end aligned on the anchor pin in the case.

Use J 4670-01 clutch spring compressor in order to compress the fourth clutch spring assembly (602). See «Special Tools»(ref-246425-S06796853872006122100000) . Remove the snap ring (601) from the driven sprocket support assembly.
Remove the spring assembly (602) and remove the fourth clutch piston assembly (603) from the driven sprocket support assembly (609).
Remove the outer seal (604) from the fourth clutch piston (603).
Remove the inner seal (605) for the fourth clutch piston from the driven sprocket support assembly hub.
Remove the oil seal rings (613) from the driven sprocket support.

Use transmission fluid in order to lubricate a new fourth clutch piston outer seal (604). Install the seal onto the fourth clutch piston assembly (603).
Use transmission fluid in order to lubricate a new fourth clutch piston inner seal (605). Install the seal into the driven sprocket support hub.
Insert the fourth clutch piston assembly (603) into the driven sprocket support (609) and align as shown.
Insert the fourth clutch return spring assembly (602) into the piston.
Use J 4670-01 in order to install the fourth clutch spring retaining ring (601). See «Special Tools»(ref-246425-S06796853872006122100000) .
If you are installing new second clutch housing oil seal rings (613), lubricate the rings. Install the oil seal rings (613) onto the driven sprocket support hub (609).

Install the selective thrust washer (630) and the thrust bearing assembly (629) onto the input clutch housing assembly (632).
Use a small screwdriver in order to align the second clutch teeth so that they slide onto the second clutch hub of the input clutch housing assembly (632).
Install the second clutch housing assembly (617) onto the second clutch hub of the input clutch housing assembly (632).
Adjust the collar on J 33381-A to 4T65-E CLUTCH & DRUM. See «Special Tools»(ref-246425-S06796853872006122100000) . Make sure that the threaded rod is fully loosened.
Install J 33381-A into the input clutch housing assembly (632). See «Special Tools»(ref-246425-S06796853872006122100000) .
Tighten the threaded rod of J 33381-A until the rod is finger tight. See «Special Tools»(ref-246425-S06796853872006122100000) .
Use J 33381-A in order to lift the input and second clutch housing assembly (617, 632). See «Special Tools»(ref-246425-S06796853872006122100000) . The sprag clutch assemblies will also be attached.
Install the input and second clutch housing assembly (617, 632) into the case. Be sure that the assembly is down all the way.

Use J 36850 or equivalent in order to secure the second clutch housing thrust washer (611) to the driven sprocket support assembly (609).
Finger start two 13 mm case cover bolts (434) into the driven sprocket support assembly (609).
Using the bolts (434), lift the driven sprocket support assembly (609) into the case and align as shown. The top of the driven sprocket support assembly (609) should be flush with the case.

Cut the oil seal rings (513, 519) from the turbine shaft (518).
Remove the oil seal rings (513, 519).
Remove the drive sprocket retaining ring (515).
Remove the drive sprocket (516) from the turbine shaft (518).

Inspect the driven sprocket (506) for the following: Worn or chipped teeth Uniform teeth size Stripped or damaged splines Bearing surface damage
Inspect the fourth clutch shaft thrust washer (505) and the driven sprocket thrust washer (508) for wear or cracks.
Inspect the drive sprocket (516) for the following: Worn or chipped teeth Uniform teeth size Stripped or damaged splines Bearing surface damage
Inspect the turbine shaft (518) for the following: A cracked sleeve Damaged bushing journals Stripped or damaged splines
Inspect the drive sprocket thrust washers (514, 517) for wear or cracks.
Insert the turbine shaft (518) into the drive sprocket (516) and attach the drive sprocket retaining ring (515).
Install J 29569-1 onto the turbine shaft (518). Coat the tool shaft with J 36850 or equivalent.
Slide the turbine shaft oil seal rings (513) into position.
Use J 29569-2 in order to size the turbine shaft oil seal rings (513).
Install J 29829-1A onto the turbine shaft (518). See «Special Tools»(ref-246425-S06796853872006122100000) . Coat the tool shaft with J 36850 or equivalent.
Slide the turbine shaft oil seal ring (519) into position.
Use J 29829-2 in order to size the turbine shaft oil seal ring (519). See «Special Tools»(ref-246425-S06796853872006122100000) .

Inspect the drive link assembly (507) for damaged, cracked or binding links.
Inspect the input speed sensor reluctor wheel (527) for damaged reluctor teeth, worn or damaged thrust surface or damaged or missing locating pins.
Use J 36850 or equivalent in order to retain the drive sprocket thrust washer (517) onto the drive sprocket (516).
Use J 36850 or equivalent in order to retain the driven sprocket thrust washer (508) onto the driven sprocket (506).
Assemble the drive (516) and driven (506) sprockets into the drive link assembly (507) according to one of the following criteria: If the old drive link is being reinstalled, position both drive link assemblies with the master link (different color) facing up or down, whichever way it was found during disassembly If a new drive link assembly is being installed, position both drive link assemblies with the master link facing upward.
Install the drive link assembly (507) and the sprockets (506, 516) into the case by hand. A slight rocking motion may be required in order to work the sprockets into place.
Install the input speed sensor reluctor wheel (527) onto the drive sprocket (516).
Install the 4th clutch shaft thrust washer (505) onto the driven sprocket (506).

Inspect the fourth clutch assembly for the following conditions: Wear or damage to the steel plates (502, 528) Peened splines, flaking or worn fiber on the fiber plate assemblies (501), (529) and (530)
Inspect the fourth clutch shaft assembly (504) for the following conditions: Cut or worn fourth clutch plate splines Stripped input sun gear splines A damaged bushing journal Cracks or damage to the hub or shaft
Install the fourth clutch shaft assembly (504) into the case through the driven sprocket. The fourth clutch shaft assembly (504) must fully seat into the input sun gear.
Install the drive link lube scoop (608) into the case.
Install the fourth clutch apply plate (528) over the fourth clutch shaft assembly and into the driven sprocket support with the machined side towards the driven sprocket.
Install the remaining fourth clutch plates, starting with a fiber plate assembly (501) and alternating with steel plates (502). Some models use fiber on one side of each inner and outer plate (529, 530). Install with the fiber side up.
The fourth clutch steel plates (502, 528) should align with the driven sprocket support as shown.

Remove the manual valve (404).
Remove the 3-4 accumulator piston cylinder (421) and the 3-4 accumulator piston O-ring seal (422). Use low pressure compressed air from the valve body side if necessary for removal.
Remove the 3-4 accumulator piston outer spring (423) and inner spring (424).
Remove the 3-4 accumulator piston (428).
Remove the 3-4 accumulator piston pin (426) from the valve body side of the case cover (401).
Remove the actuator feed limit valve spring retainer (416).
Remove the actuator feed limit valve spring (415).
Remove the actuator feed limit valve (414).

Remove the manual valve (404).
Remove the 3-4 accumulator piston cylinder (421) and the 3-4 accumulator piston O-ring seal (422). Use low pressure compressed air from the valve body side if necessary for removal.
Remove the 3-4 accumulator piston outer spring (423) and inner spring (424).
Remove the 3-4 accumulator piston (428).
Remove the 3-4 accumulator piston pin (426) from the valve body side of the case cover (401).
Remove the actuator feed limit valve spring retainer (416).
Remove the actuator feed limit valve spring (415).
Remove the actuator feed limit valve (414).
Remove the low regulator valve bore plug (444).
Remove the low regulator valve (443).
Remove the low regulator valve spring (442).

Assemble J 8092 and J 41991 for bearing removal. See «Special Tools»(ref-246425-S06796853872006122100000) .
Place the case cover (400) on a clean, flat surface with the spacer plate mating surface up.
Using the assembled tool, press the drive shaft bearing assembly (431) from the case cover (400).

Assemble J 8092 and J 41991 for bearing installation. See «Special Tools»(ref-246425-S06796853872006122100000) .
Place the case cover (400) on a clean, flat surface with the case mating surface up.
Using the assembled tool, press the drive shaft bearing (431) into the case cover (400).

Install a new 3-4 accumulator piston cylinder O-ring seal (422) onto the 3-4 accumulator piston cylinder (421).
Install the 3-4 accumulator piston outer spring (423) and inner spring (424) into the 3-4 accumulator piston cylinder (421).
Install a new 3-4 accumulator piston seal (427) onto the 3-4 accumulator piston (428).
Insert the 3-4 accumulator piston (428) into the 3-4 accumulator piston cylinder (421).
Using a slight twisting motion, insert the 3-4 accumulator piston cylinder (421) into the case cover (401).
Insert the 3-4 accumulator piston pin (426) through the front of the case cover (401) and into the 3-4 accumulator piston (428).
Install the manual valve (404) into the case cover (401).
Install the actuator feed limit valve (414) into the case cover (401).
Install the actuator feed limit valve spring (415) into the case cover (401).
Install the actuator feed limit valve spring retainer (416) into the case cover (401).

Install a new 3-4 accumulator piston cylinder O-ring seal (422) onto the 3-4 accumulator piston cylinder (421).
Install the 3-4 accumulator piston outer spring (423) and inner spring (424) into the 3-4 accumulator piston cylinder (421).
Install a new 3-4 accumulator piston seal (427) onto the 3-4 accumulator piston (428).
Insert the 3-4 accumulator piston (428) into the 3-4 accumulator piston cylinder (421).
Using a slight twisting motion, insert the 3-4 accumulator piston cylinder (421) into the case cover (401).
Insert the 3-4 accumulator piston pin (426) through the front of the case cover (401) and into the 3-4 accumulator piston (428).
Install the manual valve (404) into the case cover (401).
Install the actuator feed limit valve (414) into the case cover (401).
Install the actuator feed limit valve spring (415) into the case cover (401).
Install the actuator feed limit valve spring retainer (416) into the case cover (401).
Install the low regulator valve spring (442).
Install the low regulator valve (443).
Install the low regulator valve bore plug (444).

Install the case cover upper gasket (430) and the case cover lower gasket (429) on the case.
Use J 36850 or equivalent in order to retain the fourth clutch shaft thrust washer (432) and the drive sprocket/case cover thrust washer (514) to the case cover (400).
Make sure that the manual valve (404) is held in place and assemble the case cover (400) onto the pins in the case.
Finger start all transaxle case cover bolts (433-436) into the locations noted. Tighten: Tighten the M 6 size bolts (434, 436) to 12 N.m (106 lb in). Tighten the M 8 size bolts (435) to 25 N.m (18 lb ft). Tighten the M 6 size bolts (433) to 12 N.m (106 lb in) using J44538 . See «Special Tools»(ref-246425-S06796853872006122100000) .

Install the oil dam (27) into the case.
Assemble the manual valve link onto the manual shift detent lever/IMS detent lever.
Connect the manual valve link (402) to the manual valve (404).
Install the manual valve link spring (403).
Install the manual shift detent assembly (804) and the manual shift detent bolt (805). Tighten: Tighten the bolt to 12 N.m (106 lb in).
Carefully install the input speed sensor (440) into the case cover (400).
Install the input speed sensor clip (441) into the case cover (400).

Inspect the vehicle speed sensor assembly (10) and the vehicle speed sensor O-ring seal (11) for the following conditions: Damaged connector Cracked housing Signs of rotor damage Cuts or nicks on the O-ring seal
Install a new O-ring seal (11) on the vehicle speed sensor assembly (10).
Install the vehicle speed sensor assembly (10) into the case extension.
Install the vehicle speed sensor bolt (9). Tighten: Tighten the bolt to 12 N.m (106 lb in).

Using a small screwdriver or pick, remove the line boost valve and bushing retainer (302) from the control valve body (301).
Remove the line boost valve bore plug (303), line boost valve (304), reverse boost valve bushing (309), reverse boost valve (310), pressure regulator valve outer and inner springs (311, 312) and pressure regulator valve (313) from the control valve body (301).
Using a small screwdriver or pick, remove the 1-2, 3-4 shift solenoid valve retainer (314D) from the control valve body (301).
Remove the 1-2, 3-4 shift solenoid (SS) valve (315A), 1-2 shift valve (318) and 1-2 shift valve spring (317) from the control valve body (301).
Remove the O-ring seal (316) from the 1-2, 3-4 SS valve (315A) ONLY if it is damaged.
Using a small screwdriver or pick, remove the pressure control solenoid valve retainer (314E) from the control valve body (301).
Remove the pressure control (PC) solenoid valve (322), torque signal regulator valve (321) and torque signal regulator valve spring (320) from the control valve body (301).
Remove the O-ring seals (307, 316) from the PC solenoid valve (322) ONLY if they are damaged.
Using a small screwdriver or pick, remove the line pressure relief valve spring retainer (325) from the control valve body (301).
Remove the line pressure relief valve spring (323) and the line pressure relief valve (324) from the control valve body (301).
Using a small screwdriver or pick, remove the TCC PWM solenoid valve retainer (314F) from the control valve body (301).
Remove the TCC PWM solenoid valve (334), TCC control valve (335) and TCC control valve spring (336) from the control valve body (301).
Remove the O-ring seals (305, 306) from the TCC PWM solenoid valve (334) ONLY if they are damaged.
Using a small screwdriver or pick, remove the TCC regulator apply valve bore plug retainer (314G) from the control valve body (301).
Remove the TCC regulator apply valve bore plug (329), O-ring seal (328), TCC regulator apply valve (327) and TCC regulator apply valve spring (326) from the control valve body (301).
Using a small screwdriver or pick, remove the 2-3 shift solenoid valve retainer (314C) from the control valve body (301).
Remove the 2-3 shift solenoid (SS) valve (315B) from the control valve body (301).
Remove the O-ring seal (316) from the 2-3 SS valve (315B) ONLY if it is damaged.
Using a small screwdriver or pick, remove the 4-3 manual downshift valve retainer (314B) from the control valve body (301).
Remove the 4-3 manual downshift valve bore plug (359), 4-3 manual downshift valve (360), 4-3 manual downshift valve spring (361) and 3-4 shift valve (362) from the control valve body (301).
Using a small screwdriver or pick, remove the 3-2 manual downshift valve retainer (353) from the control valve body (301).
Remove the 3-2 manual downshift valve bore plug (354), 3-2 manual downshift valve spring (355), 3-2 manual downshift valve (356) and 2-3 shift valve (357) from the control valve body (301).
Using a small screwdriver or pick, remove the 1-2 accumulator valve retainer (314A) from the control valve body (301).
Remove the 1-2 accumulator valve bore plug (339), 1-2 accumulator valve (350) and 1-2 accumulator valve spring (351) from the control valve body (301).
Using a small screwdriver or pick, remove the 2-3 accumulator valve bushing assembly retainer (385) from the control valve body (301).
Remove the 2-3 accumulator valve bushing assembly (345), 3-4 accumulator valve (341) and 3-4 accumulator valve spring (340) from the control valve body (301).
Using a small screwdriver or pick, remove the 2-3 accumulator valve bore plug retainer (342) from the 2-3 accumulator valve bushing (345).
Remove the 2-3 accumulator valve bore plug (343), the 2-3 accumulator valve spring (346) and the 2-3 accumulator valve (344) from the 2-3 accumulator valve bushing (345).

Using a small screwdriver or pick, remove the line boost valve and bushing retainer (302) from the control valve body (301).
Remove the line boost valve bore plug (303), line boost valve (304), reverse boost valve bushing (309), reverse boost valve (310), pressure regulator valve outer and inner springs (311, 312) and pressure regulator valve (313) from the control valve body (301).
Using a small screwdriver or pick, remove the 1-2, 3-4 shift solenoid valve retainer (314D) from the control valve body (301).
Remove the 1-2, 3-4 shift solenoid (SS) valve (315A), 1-2 shift valve (318) and 1-2 shift valve spring (317) from the control valve body (301).
Remove the O-ring seal (316) from the 1-2, 3-4 SS valve (315A) ONLY if it is damaged.
Using a small screwdriver or pick, remove the pressure control solenoid valve retainer (314E) from the control valve body (301).
Remove the pressure control (PC) solenoid valve (322), torque signal regulator valve (321) and torque signal regulator valve spring (320) from the control valve body (301).
Remove the O-ring seals (307, 316) from the PC solenoid valve (322) ONLY if they are damaged.
Using a small screwdriver or pick, remove the line pressure relief valve spring retainer (325) from the control valve body (301).
Remove the line pressure relief valve spring (323) and the line pressure relief valve (324) from the control valve body (301).
Using a small screwdriver or pick, remove the TCC PWM solenoid valve retainer (314F) from the control valve body (301).
Remove the TCC PWM solenoid valve (334), TCC control valve (335) and TCC control valve spring (336) from the control valve body (301).
Remove the O-ring seals (305, 306) from the TCC PWM solenoid valve (334) ONLY if they are damaged.
Using a small screwdriver or pick, remove the TCC regulator apply valve bore plug retainer (314G) from the control valve body (301).
Remove the TCC regulator apply valve bore plug (329), O-ring seal (328), TCC regulator apply valve (327) and TCC regulator apply valve spring (326) from the control valve body (301).
Using a small screwdriver or pick, remove the 2-3 shift solenoid valve retainer (314C) from the control valve body (301).
Remove the 2-3 shift solenoid (SS) valve (315B) from the control valve body (301).
Remove the O-ring seal (316) from the 2-3 SS valve (315B) ONLY if it is damaged.
Using a small screwdriver or pick, remove the 4-3 manual downshift valve retainer (314B) from the control valve body (301).
Remove the 4-3 manual downshift valve bore plug (359), 4-3 manual downshift valve (360), 4-3 manual downshift valve spring (361) and 3-4 shift valve (362) from the control valve body (301).
Using a small screwdriver or pick, remove the 3-2 manual downshift valve retainer (353) from the control valve body (301).
Remove the 3-2 manual downshift valve bore plug (354), 3-2 manual downshift valve spring (355), 3-2 manual downshift valve (356) and 2-3 shift valve (357) from the control valve body (301).
Using a small screwdriver or pick, remove the 1-2 accumulator valve retainer (314A) from the control valve body (301).
Remove the 1-2 accumulator valve bore plug (339), 1-2 accumulator valve (350) and 1-2 accumulator valve spring (351) from the control valve body (301).
Using a small screwdriver or pick, remove the 2-3 accumulator valve bushing assembly retainer (385) from the control valve body (301).
Remove the 2-3 accumulator valve bushing assembly (345), 3-4 accumulator valve (341) and 3-4 accumulator valve spring (340) from the control valve body (301).
Using a small screwdriver or pick, remove the 2-3 accumulator valve bore plug retainer (342) from the 2-3 accumulator valve bushing (345).
Remove the 2-3 accumulator valve bore plug (343), the 2-3 accumulator valve spring (346) and the 2-3 accumulator valve (344) from the 2-3 accumulator valve bushing (345).

Install the 2-3 accumulator valve (344), the 2-3 accumulator valve spring (346) and the 2-3 accumulator valve bore plug (343) into the 2-3 accumulator valve bushing (345).
Install the 2-3 accumulator valve bore plug retainer (342) in the 2-3 accumulator valve bushing (345), into the slot indicated.
Install the 3-4 accumulator valve spring (340), the 3-4 accumulator valve (341) and the 2-3 accumulator valve bushing (345) into the control valve body (301).
Hold the 2-3 accumulator valve bushing assembly (345) in the control valve body (301). Install the 2-3 accumulator valve bushing assembly retainer (385) into the slot indicated.
Install the 1-2 accumulator valve spring (351), the 1-2 accumulator valve (350) and the 1-2 accumulator valve bore plug (339) into the control valve body (301).
Hold the 1-2 accumulator valve bore plug (339) in the control valve body (301). Install the 1-2 accumulator valve retainer (314A) into the control valve body (301).
Install the 2-3 shift valve (357), the 3-2 manual downshift valve (356), the 3-2 manual downshift valve spring (355) and the 3-2 manual downshift valve bore plug (354) into the control valve body (301).
Hold the 3-2 manual downshift valve bore plug (354) in the control valve body (301). Install the 3-2 manual downshift valve retainer (353) into the control valve body (301).
Install the 3-4 shift valve (362), the 4-3 manual downshift valve spring (361), the 4-3 manual downshift valve (360) and the 4-3 manual downshift valve bore plug (359) into the control valve body (301).
Hold the 4-3 manual downshift valve bore plug (359) in the control valve body (301). Install the 4-3 manual downshift valve retainer (314B) into the control valve body (301).
Install a new O-ring seal (316) onto the 2-3 shift solenoid (SS) valve (315B), if it was removed.
Install the 2-3 SS valve (315B) into the control valve body (301).
Install the 2-3 shift solenoid valve retainer (314C) into the control valve body (301).
Install the TCC regulator apply valve bore plug O-ring seal (328) onto the TCC regulator apply valve bore plug (329).
Install the TCC regulator apply valve spring (326), the TCC regulator apply valve (327) and the TCC regulator apply valve bore plug (329) into the control valve body (301).
Hold the TCC regulator apply valve bore plug (329) in the control valve body (301). Install the TCC regulator apply valve bore plug retainer (314G) into the control valve body (301).
Install new O-ring seals (305, 306) onto the TCC PWM solenoid valve (334) if they had been removed.
Install the TCC control valve spring (336), the TCC control valve (335) and the TCC PWM solenoid valve (334) into the control valve body (301).
Hold the TCC PWM solenoid valve (334) in the control valve body (301). Install the TCC PWM solenoid valve retainer (314F) into the control valve body (301).
Install the line pressure relief valve (324) and the line pressure relief valve spring (323) into the control valve body (301).
Compress the line pressure relief valve spring (323) into the control valve body (301). Install the line pressure relief valve spring retainer (325) into the control valve body (301).
Install new O-ring seals (307, 316) onto the pressure control (PC) solenoid valve (322), if they had been removed.
Install the torque signal regulator valve spring (320), the torque signal regulator valve (321) and the PC solenoid valve (322) into the control valve body (301).
Hold the PC solenoid valve (322) in the control valve body (301). Install the pressure control solenoid valve retainer (314E) into the control valve body (301).
Install a new O-ring seal (316) onto the 1-2, 3-4 shift solenoid (SS) valve (315A), if it was removed.
Install the 1-2 shift valve spring (317), the 1-2 shift valve (318) and the 1-2, 3-4 SS valve (315A) into the control valve body (301).
Hold the 1-2, 3-4 SS valve (315A) in the control valve body (301). Install the 1-2, 3-4 shift solenoid valve retainer (314D) into the control valve body (301).
Install the reverse boost valve (310), the line boost valve (304) and the line boost valve bore plug (303) into the reverse boost valve bushing (309).
Install the pressure regulator valve (313), the pressure regulator valve outer and inner springs (311, 312) and the reverse boost valve bushing assembly (309) into the control valve body (301).
Hold the reverse boost valve bushing assembly (309) in the control valve body (301). Install the line boost valve and bushing retainer (302) into the control valve body (301).

Install the 2-3 accumulator valve (344), the 2-3 accumulator valve spring (346) and the 2-3 accumulator valve bore plug (343) into the 2-3 accumulator valve bushing (345).
Install the 2-3 accumulator valve bore plug retainer (342) in the 2-3 accumulator valve bushing (345), into the slot indicated.
Install the 3-4 accumulator valve spring (340), the 3-4 accumulator valve (341) and the 2-3 accumulator valve bushing (345) into the control valve body (301).
Hold the 2-3 accumulator valve bushing assembly (345) in the control valve body (301). Install the 2-3 accumulator valve bushing assembly retainer (385) into the slot indicated.
Install the 1-2 accumulator valve spring (351), the 1-2 accumulator valve (350) and the 1-2 accumulator valve bore plug (339) into the control valve body (301).
Hold the 1-2 accumulator valve bore plug (339) in the control valve body (301). Install the 1-2 accumulator valve retainer (314A) into the control valve body (301).
Install the 2-3 shift valve (357), the 3-2 manual downshift valve (356), the 3-2 manual downshift valve spring (355) and the 3-2 manual downshift valve bore plug (354) into the control valve body (301).
Hold the 3-2 manual downshift valve bore plug (354) in the control valve body (301). Install the 3-2 manual downshift valve retainer (353) into the control valve body (301).
Install the 3-4 shift valve (362), the 4-3 manual downshift valve spring (361), the 4-3 manual downshift valve (360) and the 4-3 manual downshift valve bore plug (359) into the control valve body (301).
Hold the 4-3 manual downshift valve bore plug (359) in the control valve body (301). Install the 4-3 manual downshift valve retainer (314B) into the control valve body (301).
Install a new O-ring seal (316) onto the 2-3 shift solenoid (SS) valve (315B), if it was removed.
Install the 2-3 SS valve (315B) into the control valve body (301).
Install the 2-3 shift solenoid valve retainer (314C) into the control valve body (301).
Install the TCC regulator apply valve bore plug O-ring seal (328) onto the TCC regulator apply valve bore plug (329).
Install the TCC regulator apply valve spring (326), the TCC regulator apply valve (327) and the TCC regulator apply valve bore plug (329) into the control valve body (301).
Hold the TCC regulator apply valve bore plug (329) in the control valve body (301). Install the TCC regulator apply valve bore plug retainer (314G) into the control valve body (301).
Install new O-ring seals (305, 306) onto the TCC PWM solenoid valve (334) if they had been removed.
Install the TCC control valve spring (336), the TCC control valve (335) and the TCC PWM solenoid valve (334) into the control valve body (301).
Hold the TCC PWM solenoid valve (334) in the control valve body (301). Install the TCC PWM solenoid valve retainer (314F) into the control valve body (301).
Install the line pressure relief valve (324) and the line pressure relief valve spring (323) into the control valve body (301).
Compress the line pressure relief valve spring (323) into the control valve body (301). Install the line pressure relief valve spring retainer (325) into the control valve body (301).
Install new O-ring seals (307, 316) onto the pressure control (PC) solenoid valve (322), if they had been removed.
Install the torque signal regulator valve spring (320), the torque signal regulator valve (321) and the PC solenoid valve (322) into the control valve body (301).
Hold the PC solenoid valve (322) in the control valve body (301). Install the pressure control solenoid valve retainer (314E) into the control valve body (301).
Install a new O-ring seal (316) onto the 1-2, 3-4 shift solenoid (SS) valve (315A), if it was removed.
Install the 1-2 shift valve spring (317), the 1-2 shift valve (318) and the 1-2, 3-4 SS valve (315A) into the control valve body (301).
Hold the 1-2, 3-4 SS valve (315A) in the control valve body (301). Install the 1-2, 3-4 shift solenoid valve retainer (314D) into the control valve body (301).
Install the reverse boost valve (310), the line boost valve (304) and the line boost valve bore plug (303) into the reverse boost valve bushing (309).
Install the pressure regulator valve (313), the pressure regulator valve outer and inner springs (311, 312) and the reverse boost valve bushing assembly (309) into the control valve body (301).
Hold the reverse boost valve bushing assembly (309) in the control valve body (301). Install the line boost valve and bushing retainer (302) into the control valve body (301).

Inspect the oil pump drive shaft (227) for the following: A scored or rough journal surface Stripped or burred splines A cut or damaged seal
Install a new oil pump drive shaft seal (228) onto the oil pump drive shaft (227).
Install the oil pump drive shaft assembly (227) into the case cover (400).

Inspect the control valve body spacer plate and gasket assembly (396) for the following root cause: Plugged holes Damaged gasket sealing surfaces Plugged or damaged screen/seal assemblies (382)
Inspect each ball check valve seat (one at a time) on the spacer plate (370) for excessive peening. Place a ball check valve (372) on each seat Use a flashlight to look for visible light between the ball check valve and the seat.
Install 4 ball check valves (372) into the case cover (400), in the positions shown. Use J 36850 or equivalent in order to hold the ball check valves in the case cover (400).
Install the 2 larger ball check valves (373) and the 4 smaller ball check valves (372) into the control valve body (300). Use J 36850 or equivalent in order to retain the ball check valves in the control valve body (300).
Install the screen/seal assemblies (382) into the spacer plate and gasket assembly (396).
Install the NEW spacer plate and gasket assembly (396) onto the control valve body (300).
Install the bolts (368) to hold the spacer plate and gaskets onto the control valve body (300).
Install the control valve body alignment sleeve (410) into the case cover (400).
Install the control valve body (300) onto the case cover (400).
Install the transmission fluid pressure (TFP) manual valve position switch assembly (395) onto the control valve body (300).
Install the control valve body bolts (374-381, 384) as indicated.
Tighten the control valve body bolts (374-381, 384). Tighten: 374 - 12 N.m (106 lb in) 375 - 12 N.m (106 lb in) 376 - 12 N.m (106 lb in) 377 - 12 N.m (106 lb in) 378 - 12 N.m (106 lb in) 379 - 16 N.m (11 lb ft) 380 - 25 N.m (18 lb ft) 381 - 8 N.m (70 lb in) 384 - 12 N.m (106 lb in)

Remove the oil pump cover (201).
Remove the pump rotor (210) and the vane rings (209).
Remove the vanes (211), the oil seal ring (212) and the slide O-ring seal (213).
Remove the outer and the inner oil pump prime springs (222, 223).
Remove the pump slide seal (220) and the slide seal support (221).
Remove the pump slide pivot pin (215).
Remove the pump body (227) from the pump base (229).
Remove the pump pivot pin (228).

Inspect the oil pump for: Worn, scored or gouged pump slide (214) Cracks, wear or damage to the rotor (210) or the vanes (211) Cuts or damage to the seals (212, 213, 220, 221) Broken priming springs (222, 223) Damaged oil pump drive shaft bearing (208) - the bearing is not serviced separately from the rotor.
Inspect the oil pump body (228) and the base (229) for: Porosity A worn, scored or damaged pump pocket Interconnected oil passages Damaged machined surfaces
Inspect the oil pump cover (201) for cracks, wear or gouges from the pump vanes.
Install the pump pivot pin (228).
Install the pump body (227) onto the pump base (229).
Install the pivot slide pin (215).
Insert the pump slide seal (221) and the pump slide seal (220) into the pump slide (214).
Insert the pump slide (214) and the slide pivot pin (215) into the pump body (227).
Install the outer and inner priming springs (222, 223) as an assembly into the pump body (227).
Install the first vane ring into the pump body (227).
Insert the pump slide O-ring seal (213) and pump slide seal ring (212) into the pump slide (214).
Insert the rotor (210) into the pump body (227).
Install the pump vanes (211) into the rotor (210). The pump vane must be flush with the top of the rotor.
Install the second vane ring (209) onto the top of the rotor (210).
Install the oil pump assembly (200) onto the control valve assembly (300).
Install the two pump body to case bolts (230) and the nine pump cover to case cover bolts (231). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Inspect the wiring harness assembly (225) for: Cut or pinched wires Cut wire insulation Bent or broken electrical connectors Damaged terminal pins
Position the wire harness assembly (225) onto the control valve body (300) and the pump cover (201).
Mate each connector into its respective electrical component and engage the locking tabs.
Secure the wiring harness conduit into the retaining clip (226) on the pump cover (201).
Assemble the fluid temperature sensor (391) into the temperature sensor clip (390).

Inspect the control valve body cover (53) for the following conditions: Damaged or porous gasket sealing surfaces Damaged or porous casting surfaces Damaged or stripped bolt holes
Inspect the control valve body cover gaskets (54, 59) for damage. The gaskets are reusable if they are NOT damaged.
Assemble the control valve body cover inner gasket (59) to the control valve body cover (53). Use J 36850 or equivalent to retain the gasket in position.
Install the control valve body cover gasket (54) and control valve body cover (53) onto the case. Make sure the gaskets and electrical connector are positioned correctly.
Install control valve body cover bolt (56) and one control valve body cover to case stud bolt (58) in the locations shown. These bolts will properly locate the control valve body cover and gasket to the case.
Install the remaining bolts as indicated: Nine control valve body cover bolts (56) Four control valve body cover TORX® head bolts (57) Four control valve body cover to case stud bolts (58) Tighten: Tighten all bolts to 25 N.m (18 lb ft).

Remove the servo piston cylinder (114) from the servo cover (104).
Remove the O-ring seal (113) from the servo piston cylinder (114).
Remove the servo piston assembly (106-111), the servo piston spring (112) and the servo exhaust screen (115) from the servo piston cylinder (114).
Remove the servo piston seal (107) from the servo piston (108).
Use a small screwdriver in order to remove the servo piston pin retaining ring (106) from the servo piston pin (111).
Remove the servo piston (108), the servo piston cushion spring (109) and the servo piston spring retainer (110) from the servo piston pin (111).

Inspect the components of the 2-1 manual band servo for the following conditions: A damaged, worn or porous servo piston cylinder (114) A damaged, worn or porous servo piston (108) A damaged or worn servo piston pin (111) A broken or damaged servo piston spring (112) A broken or damaged servo piston cushion spring (109) A damaged or plugged servo exhaust screen (115) A damaged servo cover seal (105) A damaged servo piston seal (107) A damaged servo piston cylinder O-ring seal (113)
Assemble the servo piston spring retainer (110), the servo piston cushion spring (109) and the servo piston (108) onto the servo piston pin (111).
Use a small screwdriver in order to install the servo piston pin retaining ring (106).
Install the servo piston seal (107) onto the servo piston (108). Lubricate the servo piston seal (107) with automatic transmission fluid.
Assemble the servo exhaust screen (115) and the servo piston cylinder O-ring seal (113) onto the servo piston cylinder (114). Lubricate the servo piston cylinder O-ring seal (113) with automatic transmission fluid.
Attach the servo piston spring (112) to the servo piston assembly (106-111).
Install the servo piston and spring assembly (106-112) into the servo piston cylinder assembly (113-115) and set the assemblies aside.

Remove the seven remaining accumulator cover bolts (131) from the accumulator assembly.
Remove the accumulator cover (132) and the spacer plate assembly (134) from the accumulator housing assembly (140).
Remove the 1-2 and 2-3 accumulator pistons (136A/B), piston pins (135A/B), outer springs (138, 142 - springs are model dependent) and cushion springs (139, 143 - springs are model dependent) from the accumulator housing (140).
Remove the piston oil seal rings (137A/B) from the 1-2 and 2-3 accumulator pistons (136A/B).
Disassemble the forward band servo and 2-1 manual band servo oil pipes (124, 125) and the lube oil pipe assembly (126-130) from the accumulator cover (132) and the 2-1 manual band servo cover (104).
Disassemble the lube oil pipe (126), the hose clamps (127), the hose (128), the lube oil pipe retainer (129) and the lube oil pipe and washer assembly (130).

Inspect the accumulator housing (140), the accumulator cover spacer plate assembly (134) and the accumulator cover (132) for the following conditions: Damaged lube and servo oil pipe holes in the accumulator cover (132) Damaged, improperly machined or porous accumulator cover (132) Bent or damaged accumulator cover spacer plate assembly (134) Stripped or damaged bolt holes in the accumulator housing (140) Damaged, worn, improperly machined or porous accumulator housing (140) Leaking, loose or missing cup plugs in the accumulator housing (140)
Inspect the accumulator pistons, springs, seals and pins for the following conditions: Broken or collapsed piston outer springs (138, 142) Broken or collapsed piston cushion springs (139, 143) Bent or worn accumulator piston pins (135A/B) Damaged, worn or porous accumulator pistons (136A/B) Damaged accumulator piston seals (137A/B)
Inspect the servo and lube oil pipe components (124-130) and the 2-1 manual band servo cover (104) for the following conditions: Damaged lube and servo oil pipe holes in the servo cover (104) Damaged, improperly machined or porous servo cover (104) Bent, plugged or damaged lube and servo oil pipes (124, 125, 126, 130) Plugged or damaged lube oil hose (128) Damaged hose clamps (127) Damaged lube oil pipe retainer (129) Missing lube oil pipe washer (130)
Install the 2-3 accumulator piston oil seal ring (137B) onto the 2-3 accumulator piston (136B). Lubricate the oil seal ring with automatic transmission fluid.
Assemble the 2-3 accumulator piston pin (135B) and piston (136B).
Install the 2-3 accumulator piston springs (138, 143) and piston assembly (136B) into the accumulator housing (140).
Install the 1-2 accumulator piston oil seal ring (137A) onto the 1-2 accumulator piston (136A). Lubricate the oil seal ring with automatic transmission fluid.
Assemble the 1-2 accumulator piston pin (135A) and piston (136A).
Install the 1-2 accumulator piston springs (139, 142) and the piston assembly (136A) into the accumulator housing (140).
Assemble the accumulator cover spacer plate assembly (134) and the accumulator cover (132) onto the accumulator housing (140).
Install seven accumulator cover bolts (131). Tighten: Tighten the accumulator cover bolts to 12 N.m (106 lb in).
Assemble the lube oil pipe (126), hose (128), hose clamps (127), pipe retainer (129) and pipe with washer (130).
Assemble the 2-1 manual band servo and forward band servo oil pipes (124, 125) into the accumulator assembly (132-140).
Assemble the 2-1 manual band servo and forward band servo oil pipes (124, 125) into the 2-1 manual band servo cover (104).
Install the lube oil pipe assembly (126-130) into the accumulator assembly (132-140).

Install the 2-1 manual band servo cover seal (105) into the case. Lubricate the 2-1 manual band servo cover seal (105) with automatic transmission fluid.
Install the 2-1 manual band servo assembly (106-116) into the case. Make sure that the 2-1 manual band servo pin engages the 2-1 manual band assembly.
Install the accumulator (132-140) and 2-1 manual band servo cover assembly (104) into the case.
Install the lube oil pipe and washer assembly (130) through the case and into the lube hole in the differential carrier internal gear.
Use a screwdriver in order to lock the lube oil pipe retainer (129) into the case.
Install the three 2-1 manual band servo cover bolts (103). Tighten: Tighten the bolts to 25 N.m (18 lb ft).
Install the four accumulator cover bolts (131). Tighten: Tighten the bolts to 12 N.m (106 lb in).

Inspect the oil pan (24) for the following conditions: A damaged sealing surface A dented or cracked bottom surface
Inspect the oil pan gasket (25) for the following conditions: A bent or damaged seal core A damaged rubber seal surface A damaged gasket
Inspect the oil pan magnet (26) for damage or misalignment
Clean the oil pan (24), the oil pan gasket (25) and the oil pan magnet (26) in order to remove any sediment.
Position the transmission so that the oil pan sealing surface is facing upward.
Lubricate the oil filter seal assembly (101) with transmission fluid.
Using a socket and a plastic mallet, gently tap the oil filter seal assembly (101) into the case (3).
Install the oil filter assembly (100) into the case (3).
Install the oil pan gasket (25) onto the case (3). The old gasket is reusable if the gasket is not damaged.
Install the oil pan (24) onto the case (3).
Install the 20 oil pan bolts (23). Tighten: Tighten the bolts to 14 N.m (10 lb ft).

Disassemble the servo piston return spring (22) from the forward band servo assembly.
Remove the servo piston oil seal ring (18) from the servo piston (16).
Using a small screwdriver, remove the servo pin retaining ring (15) from the servo piston apply pin (21).
Disassemble the servo piston (16), the servo piston cushion inner spring (65), the servo piston cushion outer spring (19), the servo cushion spring retainer (20) and the servo piston apply pin (21).

Inspect the forward band servo components for the following conditions: Damaged, worn or porous servo piston (16) Damaged servo piston oil seal ring (18) Damaged, worn or porous servo cover (13) Damaged servo cover seal (14) Broken or collapsed servo piston return spring (22) Broken or collapsed servo piston cushion inner spring (65) Broken or collapsed servo piston cushion outer spring (19) Damaged or worn servo piston apply pin (21)
Assemble the servo piston (16), the servo piston cushion outer spring (19), the servo piston cushion inner spring (65), the servo cushion spring retainer (20) and the servo piston apply pin (21).
Install the servo pin retaining ring (15) onto the servo piston apply pin (21).
Install the servo piston oil seal ring (18) onto the servo piston (16).
Assemble the servo piston return spring (22) onto the servo assembly.
Position the transmission so that the oil pan is facing up.
Install the servo cover seal (14) onto the servo cover (13).
Assemble the servo assembly (15-22) into the servo cover (13). Pivot the servo assembly (15-22) into the servo cover (13) in order to prevent the piston oil seal ring from being damaged.
Install the servo and cover assembly (13-22) into the case.
Using a long screwdriver, pry against the work bench in order to compress the forward band servo assembly (13).
Hold the servo assembly compressed.
Install the 3 forward band servo cover bolts (12). Tighten: Tighten the bolts to 12 N.m (106 lb in).
Remove the long screwdriver.

Disassemble the reverse band servo piston return spring (49) from the reverse band servo assembly.
Remove the servo piston oil seal ring (43) from the servo piston (44).
Using a small screwdriver, remove the servo pin retaining ring (42) from the servo piston apply pin (48).
Disassemble the servo piston (44), the servo piston cushion springs (45, 47), the servo piston cushion spring retainer (46) and servo piston apply pin (48).

Inspect the reverse band servo components for the following conditions: Damaged, worn or porous servo piston (44) Damaged servo piston oil seal ring (43) Damaged, worn or porous servo cover (40) Damaged servo cover O-ring seal (41) Damaged servo cover retaining ring (39) Broken or collapsed servo piston return spring (49) Broken or collapsed servo piston cushion springs (45, 47) Damaged or worn servo piston apply pin (48)
Assemble the servo piston (44), the servo piston cushion springs (45, 47), the servo piston cushion spring retainer (46) and the servo piston apply pin (48).
Install the servo pin retaining ring (42) onto the servo piston apply pin (48).
Install the servo piston oil seal ring (43) onto the servo piston (44).
Assemble the servo piston return spring (49) onto the servo assembly.
Position the transmission so that the oil pan is facing down.
Install the servo cover O-ring seal (41) onto the servo cover (40).
Install the servo and cover assembly (40-49) into the case.
Use a long screwdriver in order to depress the reverse band servo cover (40) by prying against the transmission holding fixture.
Hold the reverse band servo assembly compressed.
Use a small screwdriver in order to install the reverse band servo cover retaining ring (39).
Remove the long screwdriver.

Inspect the output shaft (510) for: Damaged bushing journals Stripped splines Snap ring groove damage
Affix the outboard drive shaft retaining ring (509) and the inboard drive shaft retaining ring (509) onto the output shaft (510).
Rotate the transmission so that the oil pan flange faces downward.
Carefully install the output shaft (510) into the transmission. Extend the shaft through the differential side gear.

Remove the pin from J 3289-20 .
Remove the transmission and J 28664-B from J 3289-20 . See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove J 28664-B from the transmission. See «Special Tools»(ref-246425-S06796853872006122100000) .
Remove J44465 from J 28664-B . See «Special Tools»(ref-246425-S06796853872006122100000) .

Apply J 36850 or equivalent to a new turbine shaft O-ring seal (520).
Apply J 36850 or equivalent to the turbine shaft (518) splines.
Install the turbine shaft O-ring seal (520) onto the turbine shaft (518).
Install the torque converter assembly (1).

Transmission Fluid Pressure (TFP) Manual Valve Position Switch Assembly (34)

The automatic transmission fluid pressure (TFP) switch is attached to the valve body and consists of one fluid pressure switch that monitors TCC release pressure. This switch is used as a diagnostic tool to confirm that the TCC is actually off when it has been commanded off by the PCM.

The TCC release switch is a normally closed pressure switch. A normally closed switch allows current to flow from the positive contact through the switch to ground when no fluid is present. Fluid pressure moves the diaphragm to disconnect the positive and ground contacts, opening the switch and stopping current flow. This change in switch state electronically signals the PCM that the TCC is released.

1-2, 2-3 and 3-4 Accumulator Assemblies

Accumulator fluid is routed to each of the accumulator assemblies in preparation for upshifts. The fluid routed to the 1-2, 2-3 and 3-4 accumulators is orificed.

Reverse Band Assembly (615)

Reverse fluid exhausts from the reverse servo, the #5 ball check valve unseats, allowing reverse servo fluid to quickly exhaust at the manual valve and the reverse band releases, shifting the transmission into NEUTRAL.

Reverse Servo Assembly (39-40)

Applies the reverse band (615) in response to reverse servo fluid pressure feeding into the servo cover (40) side of the reverse servo piston (44).

Wraps around the second clutch housing (617) and holds the input carrier (672), through the reverse reaction drum (669), allowing the vehicle to move in reverse.

Applies the reverse band (615) in response to reverse servo fluid pressure feeding into the servo cover (40) side of the reverse servo piston (44).

Wraps around the second clutch housing (617) and holds the input carrier (672), through the reverse reaction drum (669), allowing the vehicle to move in reverse.

Forward Servo Assembly (15-22)

Applies and holds the forward band (688) during all forward gear drive ranges.

Forward Band Assembly (688)

Wraps around and holds the 1-2 support outer race (687) during all forward gear drive ranges.

Applies and holds the forward band (688) during all forward gear drive ranges.

Wraps around and holds the 1-2 support outer race (687) during all forward gear drive ranges.

Manual 2-1 Servo Assembly (104-115)

Applies the manual 2-1 band (680) during manual second and manual first gear ranges.

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