Automatic Transaxle - 4T65-E - Overhaul: Removal & Installation Chevrolet Uplander I

Removal Procedure

1. Remove the drive shaft retaining ring (509).
2. Rotate the transaxle 90 degrees.
3. Remove the transfer case lower brace bolt (904).
4. Rotate the transaxle 90 degrees.
5. Remove the transfer case side brace bolts (903). Remove the side brace (905).
6. Remove the transfer case to case bolts (907, 909, 910).
7. Remove the transfer case assembly (908) from the transmission case (3).
8. Remove the transfer case lower brace bolts (903).
9. Remove the transfer case lower brace (906).
10. Remove the case extension seal (8) from the transfer case (908).
11. Position the transaxle so that the case side cover is facing down.
12. Remove the oil dam (901) from the transaxle.
13. Install the transfer case assembly onto the J 44755 . Position the carrier onto the post of the fixture.
14. Install the retaining bolts. Tighten: Tighten the retaining bolts to 50 N.m (37 lb ft).
15. Attach the J 6125-1B to J 44467 . See «Special Tools»(ref-246425-S06796853872006122100000) . Install the J 44467 into the snap ring groove on the output shaft (510). See «Special Tools»(ref-246425-S06796853872006122100000) . Tighten J 44467 securely to the output shaft. See «Special Tools»(ref-246425-S06796853872006122100000) .
16. Remove the output shaft with the slide hammer impact.
17. Remove the final drive sun gear (697).
18. Remove the selective washer (902).
19. Remove the parking gear (696) and the parking gear thrust bearing (695).
20. Remove the final drive sun gear shaft (689).

1. Use a long screwdriver in order to depress the reverse band servo cover (40) by prying against the transmission holding fixture.
2. Use a small screwdriver in order to pry out the retaining ring (39) from the reverse band servo cover.
3. Remove the long screwdriver. The servo assembly will push the servo cover (40) up.
4. Remove the servo cover (40) and the servo cover O-ring seal (41).
5. Remove the reverse band servo assembly (42-48).
6. Remove the reverse band servo piston spring (49).

1. Position the transmission so that the oil pan is facing up.
2. Use a long screwdriver in order to compress the forward band servo assembly cover (13) by prying against the work bench.
3. Hold the servo assembly compressed.
4. Remove the three forward band servo cover bolts (12).
5. Remove the long screwdriver. The servo assembly will push the servo cover out. If the servo cover does not push out, tap it with a rubber mallet.
6. Remove the servo cover (13) and remove the cover seal (14).
7. Remove the servo assembly (15-21).
8. Remove the piston spring (22) from the forward band servo.

1. Remove the 20 oil pan bolts (23).
2. Remove the oil pan (24).
3. Remove the oil pan gasket (25).
4. Use a screwdriver in order to pry the oil filter assembly (100) out of the case. Do not damage the case sealing surface.
5. Use a small screwdriver in order to pry the oil filter seal assembly (101) out of the case. Do not damage the case sealing surface.

1. Remove the four indicated accumulator cover bolts (131) from the 1-2 and 2-3 accumulator cover (132).
2. Remove the three indicated bolts (103) from the manual 2-1 band servo cover (104).
3. Use a large screwdriver in order to gently pry the lube oil pipe retainer (129) from the case.
4. Remove the lube oil pipe (130) from the front differential carrier internal gear lube hole.
5. Remove the 1-2 and 2-3 accumulator assembly (132-140), the pipe assembly (124-126) and the manual 2-1 band servo cover (104).
6. Remove the manual 2-1 band servo assembly (106-116) out of the case at the same time.
7. Remove the cover seal (105) from the manual 2-1 band servo assembly.

1. Using a small screwdriver, pry the wiring harness (224/225) electrical connectors off of the following components: Automatic transaxle fluid pressure manual valve position switch assembly (395) 1-2, 3-4 Shift solenoid valve assembly (315A) 2-3 Shift solenoid valve assembly (315B) TCC PWM solenoid valve assembly (334) Pressure control solenoid valve assembly (322) Automatic transaxle input speed sensor assembly (440) IMS (811)
2. Gently pull the automatic transaxle fluid temperature sensor (391) from it's clip.
3. Lift the wiring harness assembly (225) off of the transaxle.

1. Remove the eleven indicated oil pump bolts (230, 231).
2. Do not remove the one oil pump cover bolt (205) at this time.
3. Remove the one wiring harness clip (390).
4. Lift the oil pump assembly (200) off of the control valve body (300).
5. Set the oil pump assembly (200) on its cover.

1. Remove the indicated control valve body bolts (374-381, 384).
2. Carefully lift the fluid pressure manual valve position switch assembly (395) off of the control valve body (300). Handle the switch assembly carefully, it is very delicate.
3. Remove the control valve body assembly (300).
4. Remove the two retainers (368) from the valve body assembly.
5. Remove the spacer plate and gasket assembly (396) and discard with the two screen/seal assemblies (382) from the valve body (300). Remove the six ball check valves (372, 373) from the valve body (300). Remove the case cover pin (410).
6. Remove the four ball check valves (372) from the case cover (400).

Scheme 98

Remove the oil pump drive shaft assembly (227) from the case cover (400).

1. Position the transmission so that the vehicle speed sensor (10) is facing up.
2. Remove the vehicle speed sensor bolt (9).
3. Remove the vehicle speed sensor (10).

1. Remove the four case extension bolts (5).
2. Remove the case extension assembly (6) and remove the extension seal (8).
3. Leave the differential carrier thrust washer (714) and the bearing (715) on the carrier.
4. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position.
5. Place the J 42562 Axle Removal Wedge between the end of the output shaft and the differential pinion shaft. See «Special Tools»(ref-246425-S06796853872006122100000) .
6. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (509) and push the output shaft through the differential side gear.
7. Remove the differential carrier assembly (700).
8. Using snap ring pliers remove the compression ring (509) from the output shaft.
9. Pull the output shaft (510) out of the transmission.

1. Remove the manual shift detent bolt (805).
2. Remove the manual shift detent assembly (804).
3. Compress the manual valve link spring (403) from the manual valve (404).
4. Lift the manual valve link (402) off of the manual valve (404).
5. Position the manual valve link (402) so that the valve will not interfere with the case cover removal.
6. Remove the oil dam (27) from the case.
7. Using a small screwdriver, pry the input speed sensor clip (441) out of the case cover (400).
8. Carefully pull the input speed sensor (440) out of the case cover (400).

1. Remove the indicated case cover bolts (434-436).
2. Use J44538 to remove case cover bolt (433). See «Special Tools»(ref-246425-S06796853872006122100000) .
3. Lift the case cover assembly (400) off of the case.
4. Remove the thrust washer (432).
5. Remove the upper (430) and the lower (429) case cover gaskets.

1. Remove the fourth clutch fiber and steel plates (501, 502) or (529, 530),some models.
2. Remove the fourth clutch apply plate (528).
3. Remove the fourth clutch shaft assembly (504).
4. Remove the drive link lube scoop (608).

1. Remove the fourth clutch shaft thrust washer (505).
2. Remove the drive sprocket thrust washer (514). It may be stuck to the case cover
3. Remove the speed sensor reluctor wheel (527).
4. Note the location of the master link on the drive link assembly (507). It is the one link that is a different color than the rest. It may be facing up or down towards the case. The drive link assembly (507) must be in the same position during assembly.
5. Lift the drive and driven sprockets (516, 506) with the drive link assembly (507) out of the case. Lift both sides evenly It may be necessary to tap the turbine shaft (518) up gently with a rubber mallet
6. Remove the drive and driven sprocket thrust washers (517, 508). They may be stuck to the sprockets

1. With your fingers, insert two 13 mm channel plate bolts (434) into the driven sprocket support assembly (609).
2. Grasp the bolts and lift the support assembly from the case.
3. Remove the thrust washer (611) from the second clutch housing. The washer may be stuck to the support assembly.

1. Adjust the collar on tool J 33381-A to the 4T65-E CLUTCH & DRUM setting. See «Special Tools»(ref-246425-S06796853872006122100000) . Make sure that the threaded rod is fully loosened.
2. Install J 33381-A into the second clutch housing assembly (617). See «Special Tools»(ref-246425-S06796853872006122100000) .
3. Tighten the threaded rod of J 33381-A until the rod is finger tight. See «Special Tools»(ref-246425-S06796853872006122100000) .
4. Lift up J 33381-A with the second clutch housing (617) and the input clutch housing (632) attached. See «Special Tools»(ref-246425-S06796853872006122100000) . The sprag clutch assemblies will also be attached.
5. Place the complete assembly on the bench.
6. Loosen the threaded rod of J 33381-A . See «Special Tools»(ref-246425-S06796853872006122100000) .
7. Remove J 33381-A from the assembly. See «Special Tools»(ref-246425-S06796853872006122100000) .
8. Lift the second clutch housing (617) off of the input clutch housing.
9. Remove the input clutch housing thrust bearing (629) from the input housing.
10. Remove the selective thrush washer (630) from the input clutch housing (632).

Scheme 99

Tilt the band in order to disengage the band from the anchor pin in the case. Remove the reverse band assembly (615).

Scheme 100

Remove the reverse reaction drum (669).

1. Remove the two case extension bolts (5).
2. Remove the case extension assembly (6) and remove the seal (8).
3. Remove the differential carrier thrust washer (715).
4. Remove the differential carrier thrust bearing (714).

1. Remove the differential carrier assembly (700).
2. Remove the differential carrier sun gear (697).
3. Remove the park gear (696).
4. Remove the thrust bearing (695) from the differential carrier internal gear.
5. Remove the shaft differential carrier sun gear (689).

1. Position the transmission so that the case cover joint is facing upward.
2. Remove the input carrier assembly (672).
3. Remove the input carrier, reaction carrier lube dam (673). The dam may be stuck to the input carrier assembly.
4. Remove the thrust bearing (674) from the reaction carrier.
5. Remove the reaction carrier assembly (675).

1. Remove the thrust bearing (676) from the reaction sun gear.
2. Remove the reaction sun gear assembly (678).
3. Tilt the band in order to disengage the manual 2-1 band assembly (680) from the anchor pin. Remove the manual 2-1 band assembly from the case.

1. Install J 38358-A onto the 1-2 support drum assembly (681-687).
2. Lift J 38358-A with the 1-2 support drum out of the case.
3. Tilt the forward band assembly (688) in order to disengage the band from the anchor pin in the case. Remove the forward band assembly.

1. Remove the bearing (691) from the differential carrier internal gear.
2. Use J 28585 or a large screwdriver in order to remove the differential carrier internal gear snap ring (692).
3. Lift the differential carrier internal gear assembly (693) out of the case by depressing the park pawl assembly in order to clear the case.

1. Use side cutting pliers in order to remove the manual shift shaft pin (801).
2. Disconnect the manual valve link (402) from the IMS/detent lever assembly (811).
3. Remove the internal mode switch (IMS)/detent lever (811) and remove the park pawl actuator assembly (800).
4. Position the transmission so that the reverse band servo bore is facing upward.
5. Use a small screwdriver in order to pry the manual shift shaft seal (806) from the case.
6. Remove the park pawl actuator guide pin (808).
7. Remove the park pawl actuator guide assembly (809) from the case.
8. Remove the actuator guide seal (810) from the guide.

1. Insert the three J 41103-1 puller legs under the Torque Converter Seal (525).
2. Insert the J 41103-3 support body over the drive sprocket support (522).
3. Insert the J 41103-2 puller bridge over the J 41103-3 support body. Connect the J 41103-1 puller legs into the slots on the J 41103-2 bridge.
4. Tighten the forcing screw on the J 41103-2 puller bridge until the J 41103-1 puller legs remove the torque converter seal (525).

1. Inspect the drive sprocket support (522) for the following conditions: Damaged splines A damaged drive sprocket support bearing A damaged turbine shaft bushing (pressed inside the support)
2. Remove the drive sprocket support bearing only if the bearing is damaged.
3. Remove the drive sprocket support assembly only if the support is damaged.
4. Assemble J 23907 and J 26941 .
5. Use J 23907 and J 26941 in order to remove the bearing assembly (521) from the drive sprocket support.
6. Remove the four drive sprocket support bolts (524).
7. Remove the drive sprocket support assembly (522).

Installation Procedure

1. Inspect the park system components for the following conditions: A worn park pawl actuator guide (809) A damaged or bent park pawl actuator assembly (800) A damaged internal mode switch (IMS) detent lever (811) A bent or damaged manual valve link (402) A kinked or bent manual valve link spring (403)
2. Use a 9/16 inch socket and a hammer in order to install the manual shift shaft seal assembly (806) into the case.
3. Install a new park pawl actuator guide O-ring seal (810) onto the park pawl actuator guide (809).
4. Install the actuator guide assembly into the case.
5. Align the slot for the actuator guide pin (808) in the park pawl with the pin hole in the case.
6. Use a mallet in order to install the actuator guide pin (808).
7. Assemble the IMS (811) onto the park pawl actuator assembly (800).
8. Install the IMS detent lever assembly (811) and the park pawl actuator assembly (800) into the case.
9. Align the groove for the manual shift shaft pin with the pin hole in the case.
10. Use a mallet in order to install the manual shift shaft pin (801).

1. Install the case extension seal (8) using J 36850 in order to retain.
2. Line up the notch (1) to the hole in the case and install the oil dam (901).
3. Install the transfer case lower brace (906).
4. Install the transfer case lower brace bolts (903). Hand tighten.
5. Install the transfer case assembly (908) onto the transmission case (3).
6. Install the 5 transfer case to case bolts (907, 909, 910).
7. Torque the bolts in the following sequence: Tighten 2 transfer case bolts (1, 2): Tighten: First pass 35 N.m (26 lb ft) Final Pass an additional 160 degrees
8. Tighten 1 transfer case bolt (3): Tighten: First pass 35 N.m (26 lb ft) Final Pass an additional 70 degrees
9. Tighten 2 transfer case bolts (4, 5): Tighten: Tighten transfer case bolts (4, 5) to 40 N.m (30 lb ft).
10. Install the transfer case side brace (905) to case.
11. Install the transfer case side brace to case bolts (903). Hand tighten the bolts.
12. Torque the bolts in the following sequence (1, 2, 3, 4, 5). Tighten: Tighten the transfer case side brace bolts to 31 N.m (23 lb ft).
13. Install the transfer case lower brace to case bolt (904). Tighten: Tighten the transfer case lower brace bolt to 56 N.m (42 lb ft).
14. Tighten the transfer case lower brace to case bolts (903). Tighten: Tighten the transfer case lower brace bolts to 31 N.m (23 lb ft).