Automatic Transaxle Overhaul & Testing - 4T65-E: Diagnosis Chevrolet Venture I

TROUBLE SHOOTING

Note. For clutch and band applications, see CLUTCH & BAND APPLICATIONS .

PRELIMINARY INSPECTION

1. Check fluid level and condition. Check PCM memory for stored Diagnostic Trouble Codes (DTC). See HYDRA-MATIC 4T65-E ELECTRONIC CONTROLS article. If no DTCs are present, go to next step. If DTCs are present, diagnose and repair first.
2. Perform road test. See «ROAD TEST»(ref-11645-S37310877132000112200000) under PERFORMANCE TESTS. During road test, record shift points. If shift point timing or shifting is incorrect, see HYDRA-MATIC 4T65-E ELECTRONIC CONTROLS article.
3. If shift(s) is too harsh or too soft, check hydraulic pressure. See «HYDRAULIC PRESSURE TESTS»(ref-11645-S28750348212000112200000) under PERFORMANCE TESTS. For specific complaints, attempt diagnosis by symptom. See «SYMPTOM DIAGNOSIS»(ref-11645-S20928953892000112200000) .

SYMPTOM DIAGNOSIS

Note. PCM controls TCC, PWM solenoid, 1-2 and 2-3 shift solenoids.

ROAD TEST

Note. Before road test procedures are performed, engine and transaxle must be at operating temperature. Torque converter clutch will not engage if transaxle fluid has not reached a minimum temperature of 46°F (8°C), and engine coolant has not reached operating temperature of 122°F (50°C).

Road Test Procedure

Perform road test with scan tool connected to vehicle. PCM calculates upshift points based primarily on throttle position and vehicle speed. When PCM determines a shift should occur, an electrical signal is sent to shift solenoids. Solenoids move shift valves to perform shift. A scan tool should be used during road test to monitor various transaxle functions. Some scan tools are capable of recording shift point information. Check scan tool instruction manual to determine if this test is available.

Inspection

Torque converter must be replaced for any of the following reasons

1. Damage To Oil Pump Assembly
2. Metal Particles Present In Oil
3. Leaks In Hub Weld Area
4. Crankshaft Pilot Broken Or Damaged
5. Hub Scored Or Damaged
6. Stator Failure
7. Torque Converter Imbalance
8. Engine Coolant Contamination
9. Excessive End Play

Stall Speed Test

Manufacturer does not recommend testing torque converter stall speed.

Noise Test

Note. Torque converter whine should not be confused with pump whine, which is usually noticeable in all gear ranges. Pump whine will vary with pressure.

1. Torque converter whine is usually noticed when vehicle is stopped and transaxle is in Reverse or Drive. Whine will increase when engine RPM is increased and will stop when vehicle is moving or when torque converter clutch is applied.
2. Start engine, and allow it to reach normal operating temperature. Apply parking and service brakes. Put transaxle in Drive. Depress accelerator and increase engine speed to about 1200 RPM for no more than 6 seconds. DO NOT load transaxle for more than 6 seconds, or transaxle damage may occur. Torque converter noise will increase under this load.

Cleaning & Inspection

Clean transaxle case thoroughly with solvent, and then air dry. Inspect for loose, cross-threaded or damaged pipe fittings on transaxle oil cooler. Check for damaged sealing surfaces or for case porosity. Check for stripped or damaged bolt holes. Check for damaged oil passages, snap ring grooves or housing splines. Check for loose, missing or damaged band anchor pins. Ensure torque converter oil seal drain back hole is not plugged. Inspect for loose, plugged or damaged transaxle vent. Check for loose, cross-threaded or damaged oil pressure test hole plug.

Inspect drive sprocket support and bearing for damage. Remove drive sprocket support and bearing only if damage is visible.

Inspection & Reassembly

1. Inspect for worn parking pawl actuator guide or cracked or bent parking pawl actuator. Check for damaged manual shift detent lever. see scheme 40 Check for worn, stripped or bent shift shaft, or bent or damaged manual valve spring link. Check for bent or kinked manual valve link spring. see scheme 29 Replace components as necessary.
2. Install NEW shift shaft seal into case using 9/16" socket and hammer. Install NEW parking pawl actuator guide "O" ring seal onto parking pawl actuator guide. Install actuator guide into case. Align slot for actuator guide pin in parking pawl with pin hole in case. Install actuator guide pin using rubber mallet.
3. Install shift shaft into case. Align groove for manual shift shaft pin with pin hole in case. Install shaft pin using rubber mallet. Position transaxle with case cover flange facing up. Install parking pawl actuator. Assemble manual shift detent lever onto actuator and onto shift shaft. Install nut on shift shaft and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).

Inspect differential carrier (final drive) internal gear for damaged or worn bushings, plugged lube oil holes, damaged case splines, damaged or worn gear teeth, damaged parking pawl or snap ring. Replace components as necessary.

1. Inspect differential carrier for damaged or worn teeth, roller bearings, washers or pins on differential planetary pinion gear. Check for damaged or worn teeth or splines on differential carrier sun gear.
2. Check for damaged or worn teeth, splines or thrust washers on differential side gear. Check for damaged or worn teeth, thrust washers or shaft on differential pinion gear. Check for damaged or worn lugs or splines on parking gear. Check for damaged vehicle speed sensor reluctor wheel.
3. Check for damaged differential carrier, sun gear or internal gear thrust bearings. Check for damaged differential carrier housing. Inspect differential carrier sun gear shaft for damaged or worn splines, cracks at lube oil holes, or damaged or worn bearing journals.
4. Using feeler gauge, measure differential carrier planetary pinion gear end play. End play should be.009-.025 " (.23-.64 mm). see scheme 42 If end play is not as specified, repair differential carrier assembly as necessary.

Inspect case extension for damaged or porous sealing surfaces, damaged bolt holes, worn or damaged differential carrier bushing or output shaft bearing. Repair as necessary.

Inspect forward band for damaged or worn friction material. Check for damaged apply or anchor pin. Inspect differential carrier internal gear thrust washer for damage. Replace components as necessary.

Inspect 1-2 support drum for scored or burned contact surface from 2-1 manual band. Check for damaged or worn forward drum bushing. Check for damaged or worn 1-2 support roller clutch inner race. Check for damaged or worn 1-2 roller clutch assembly. Inspect for damaged thrust bearing. Replace components as necessary.

Inspect 2-1 manual band for cracked, separated or worn friction material. Inspect for cracks around apply lugs. Replace components as necessary.

Inspect reaction sun gear and drum for worn or scored bushings. Check for damaged reaction sun gear teeth. Check band apply area of drum for discoloration or wear. Inspect welds connecting sun gear to drum for voids or cracks. Check for worn or damaged 1-2 support outer race. Replace components as necessary.

1. Using feeler gauge, check for excessive pinion gear end play in input carrier and reaction carrier assemblies. End play should be.009-.030" (.23-.76 mm). If end play is not as specified, replace appropriate component. (Scheme 7)
2. Inspect thrust bearings for damaged cage, or damaged or missing rollers. Inspect reaction carrier for damaged pinion teeth or internal gear teeth. Inspect input carrier for damaged pinion or spline teeth. Replace components as necessary.

Scheme 7

Scheme 8

1. Check for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25 degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10 degree sides.
2. Inspect reverse reaction drum for cracks, damaged splines or distortion. see scheme 38 Replace drum if necessary.

Inspect outer races for worn or damaged splines, scoring on inside diameter of races, wear or cracks. Inspect sprag components for flat spots. Inspect cage assemblies for distortion or broken ribbon tabs. Inspect end bearings and center bearing for cracks. Check input sun gear spacer for worn or damaged splines, or wear and cracks. Inspect input sun gear for worn or damaged splines or plugged lube holes or cracks. Replace components as necessary.

1. Inspect input clutch housing for plugged fluid feed passages, worn or damaged splines, or input shaft bushing wear. Check seal ring groove for nicks or burrs. Check for cracks or blocked fluid passages in input shaft. Inspect for damage or wear to thrust bearing, located in input clutch housing.
2. With check ball in seated position, add ATF to input clutch housing, and inspect for leaks. If check ball assembly leaks, see «INPUT CLUTCH HOUSING CHECK BALL VALVE»(ref-11645-S16677095632000112200000) . Inspect input clutch piston for cracks or damage to seal grooves. Check for wear on piston lugs. Inspect input clutch and 3rd clutch spring assemblies for damaged cage or distorted or missing springs. DO NOT attempt to reuse 3rd clutch piston and seal. Check input shaft thrust bearing for damage or wear. Replace components as necessary.

1. Check for leaking or damaged check ball valve in 2nd clutch housing. If check ball assembly leaks, see «2ND CLUTCH HOUSING CHECK BALL VALVE»(ref-11645-S24820207032000112200000) . Turn housing in order to seat check ball valve. Use transaxle fluid to check 2nd clutch housing check ball for leaks. Check for scored or worn bushings. Check for discolored band surface or wear on drum caused by excessive heat. Check for flatness of band surface on drum.
2. Check for damaged reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25 degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10° degree sides. Check for cracks in welds. Inspect backing plate and waved plate for cracks and heat spots. Inspect steel and composition plates for wear, lining separation, pitting, flaking or damage. Inspect apply ring and spring assembly for damage. Inspect piston and piston seals for damage. Inspect 2nd clutch housing for damaged inner piston seal. Inspect housing for warpage.

Inspect reverse band for cracks, scoring, lining separation or wear on fiber material. Inspect apply lug for cracks. Replace components as necessary.

1. Check for worn or cut oil seal rings. Check for rolled or cut 2nd clutch housing oil seal rings. Check for damage to piston seal surface in driven sprocket support assembly. Check for blocked or porous fluid passages in driven sprocket support assembly.
2. Inspect 4th clutch piston for damage. Check thrust washer from 2nd clutch housing for cracks or distortion. Check 4th clutch spring assembly for distorted or missing springs. Check driven sprocket bearing assembly for foreign material and missing, flat or damaged rollers. Replace Teflon oil seal rings if rings are cut or damaged, or if complete overhaul is being performed. Check all seal ring grooves for debris, burrs or damage.

1. Inspect sprocket teeth for wear or chips. Ensure teeth size are uniform. Check for stripped or damaged splines. Check bearing surface for damage. Check thrust washers for wear or cracks. Replace components as necessary.
2. Insert turbine shaft into drive sprocket and attach retaining ring. Install appropriate seal installer onto turbine shaft. Coat shaft with petroleum jelly. Slide turbine shaft seals into position. Size seals with appropriate seal sizer.

Inspect drive chain assembly for cracks, binding links or damage. Check input speed sensor reluctor wheel for damaged teeth, worn or damaged thrust surface and damaged or missing locating pins.

Inspect 4th clutch assembly steel plates for wear or damage. Check composition plates for peened splines, flaking or wear. Check 4th clutch shaft assembly for cut or worn 4th clutch plate splines. Check for damage or wear to shaft bushing. Inspect for damaged bushing journal. Inspect input sun gear for stripped splines. Check for cracks or damage to hub shaft. Replace components as necessary.

1. Inspect 3-4 accumulator piston cylinder for porosity, scored pin or nicked or grooved piston sleeve. Check piston pin for scoring and free movement in piston bore. Check springs for distorted or broken coils. Inspect piston cylinder for porosity or cracks. Check for rough or scored seal surface, or cut seal. Inspect check ball, spring and bore plug.
2. DO NOT remove blow-off check balls unless damaged. Inspect manual valve, link and spring link for damage. Check manual valve for binding or looseness in case cover. Check case cover plugs and orifice cup plug. Replace plugs if loose, plugged or missing.
3. Inspect shaft bearing for damage. DO NOT remove bearing unless bearing is damaged. Inspect oil seal for missing garter spring or for cut lip seal. Check case cover for porosity, interconnected fluid passages, cracks or rough machined surfaces. Check input speed sensor for damaged or missing magnet. Check for damaged housing, bent or missing electrical terminals, or damaged speed sensor clip.

Inspect output shaft for damaged bushing journals, stripped splines or retaining ring groove damage. see scheme 31

Check for damaged connector, cracked housing, signs of rotor damage or cuts or nicks on seal. Install NEW seal over speed sensor. Install speed sensor into case extension and tighten bolt to specification. See TORQUE SPECIFICATIONS .

Clean valves, springs and bushings in solvent. DO NOT use shop rags to clean valve body components. Inspect valves and bushings for scoring, nicks and scratches. Inspect springs for damaged or distorted coils. Inspect valve body casting for porosity, interconnected oil passages and damaged machined surfaces. Inspect fluid pressure manual position switch assembly for damaged electrical connectors, seals, switch membranes or debris.

1. Inspect control valve body spacer plate for plugged holes, damaged sealing surfaces, or plugged or damaged screen/seal assemblies. Inspect each check ball seat on spacer plate for excessive peening. Place check ball on each seat. Using flashlight, look for visible light between check ball and seat. (Scheme 9) If light is visible between check ball and seat, replace spacer plate.
2. Install 4 check balls into case cover. see scheme 25 Use petroleum jelly to hold check balls in position. Install 2 large check balls and 4 small check balls into control valve body. (Scheme 10)
3. Install solenoid screen/seal assemblies into spacer plate. Install case cover guide pin into case cover. Install valve body-to-spacer plate gasket, spacer plate and case cover-to-spacer plate gasket onto control valve body. Install bolts to hold spacer plate and gaskets onto control valve body. see scheme 26
4. Install control valve body onto case cover. Use case cover pin and turbine sleeve in case cover as guides. Ensure check balls do not drop out of control valve body during reassembly. Install fluid pressure manual valve position switch onto control valve body.
5. Install control valve body bolts. See «VALVE BODY BOLT SPECIFICATIONS»(ref-11645-S07883515462001042500000) table under TRANSAXLE REASSEMBLY. Finger tighten bolts to prevent cross-threading. Tighten bolts in a spiral pattern starting with bolts at center of control valve body. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000). If bolts are tightened at random, valve bores may become distorted and prevent proper valve operation.

Scheme 9

Scheme 10

1. Inspect pump body for porosity, interconnected oil passages, or damaged inner pump area surface or machine facing. Check slide, springs, rotor and vanes for damage. Inspect slide seal, slide support and seals for damage. see scheme 64
2. Measure undamaged area of rotor, vane or slide to check for proper size. See «OIL PUMP COMPONENT SPECIFICATIONS»(ref-11645-S30620515022000112200000) table. see scheme 65 Ensure replacement parts are matched to fit within specification.

Note. Laser marks on oil pump body indicate size of selective parts which were used in assembly. If correct parts are not selected for replacement, damage to oil pump and transaxle will occur. Oil pump components are matched sets. DO NOT mix old and new parts.

OIL PUMP COMPONENT SPECIFICATIONS

Inspect wiring harness for cut or pinched wires, cut wire insulation, bent or broken electrical connectors or damaged terminals. Position wire harness assembly onto control valve body and oil pump. Mate each connector into its respective electrical component and engage locking tabs. see scheme 22 Secure harness conduit into retaining clip on oil pump cover. Install A/T fluid temperature sensor into retaining clip.

1. Inspect case side cover for damaged or porous gasket sealing surfaces, and damaged or stripped bolt holes. Inspect case side cover gasket and channel plate seal for damage. Gasket and seal can be reused if not damaged.
2. Install channel plate seal to cover. see scheme 26 Use petroleum jelly to hold seal in position. Install cover gasket and case side cover onto transaxle case. Ensure gasket, seal and electrical connectors are positioned correctly. Install 2 flange bolts at 3 o'clock and 9 o'clock positions. see scheme 21 These bolts locate cover and gasket to transaxle case. Install remaining bolts in specified locations. See «CASE COVER BOLT SPECIFICATIONS»(ref-11645-S18217872682001042500000) table under TRANSAXLE REASSEMBLY. Tighten cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).

1. Check for damaged, worn or porous servo piston cylinder. Check for damaged, worn or porous servo piston. Check for damaged or worn servo piston pin. Check for broken or damaged servo piston spring or cushion spring. Check for damaged or plugged servo exhaust screen. Check for damaged servo cover gasket, servo piston seal or servo piston cylinder "O" ring seal.
2. Install servo piston spring retainer, cushion spring and servo piston onto servo piston pin. Install servo piston pin retaining ring. Install servo piston seal onto piston. Lubricate seal with transaxle fluid. Install servo exhaust screen and servo piston cylinder "O" ring seal onto cylinder. Lubricate "O" ring seal with ATF. Attach servo piston spring to piston assembly. Install servo piston assembly into cylinder assembly and set assemblies aside.

1. Inspect for damaged lube and servo oil pipe holes in accumulator cover. Check for damaged, improperly machined or porous accumulator cover or housing. Check for bent or damaged accumulator spacer plate. Check for damaged accumulator cover gaskets. Check for stripped or damaged bolt holes in accumulator housing. Check for leaking, loose or missing cup plugs in accumulator housing.
2. Inspect for broken or collapsed piston springs (inner, outer or cushion). Check for bent or worn accumulator piston pins. Check for damaged, worn or porous accumulator pistons. Check for damaged accumulator piston seals. Replace components as necessary.
3. Check for damaged lube and servo oil pipe holes in servo cover. Check for damaged, improperly machined of porous servo cover. Check for bent, plugged or damaged lube and servo oil pipes. Check for plugged or damaged lube oil hose. Check for damaged hose clamps, lube oil pipe retainer or missing lube oil pipe washer.

1. Check for damaged sealing surface. Check for dented or cracked pan surface. Inspect oil pan gasket for bent or damaged seal core, damaged rubber seal surface or damaged gasket. Check oil pan magnet for damage or misalignment. Clean oil pan, gasket and magnet. see scheme 18
2. Position transaxle with oil pan sealing surface facing up. Using socket and plastic mallet, gently tap oil filter seal into case. Gently tap oil filter into case. Install oil pan gasket onto transaxle case. Install oil pan and oil pan bolts. Tighten oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).

1. Inspect for damaged, worn or porous servo piston. Check for damaged servo piston seal or servo cover seal. Check for broken or collapsed servo piston spring or cushion spring. Check for damaged or worn servo piston pin or servo cover. Replace components as necessary.
2. Assemble servo piston, servo piston cushion spring, retainer and servo piston pin. Install servo pin retaining ring onto servo piston pin. Install servo piston oil seal ring onto servo piston. Install servo piston spring onto servo assembly. see scheme 18
3. Position transaxle with oil pan facing up. Install servo cover seal onto servo cover. Assemble servo assembly into servo cover. Pivot servo into cover to prevent piston seal from being damaged. Install servo and cover into case.
4. Using long screwdriver, pry against bench and compress forward band servo assembly. Hold servo assembly compressed and install forward band servo cover bolts, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).

1. Inspect for damaged, worn or porous servo piston. Check for damaged servo piston seal or servo cover seal. Check for broken or collapsed servo piston spring or cushion spring. Check for damaged or worn servo piston pin or servo cover. Replace components as necessary.
2. Assemble servo piston, servo piston cushion spring, retainer and servo piston pin. Install servo pin retaining ring onto servo piston pin. Install servo piston oil seal ring onto servo piston. Install servo piston spring onto servo assembly. see scheme 18
3. Position transaxle with oil pan facing down. Install servo cover seal onto servo cover. Install servo and cover assembly into case. Using long screwdriver, pry against transaxle holding fixture and compress reverse band servo cover. Hold servo assembly compressed and install retaining ring.