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

GEAR RATIOS

TRANSAXLE GEAR RATIOS

ON-VEHICLE SERVICE

The following components can be serviced without transaxle removal

1. Final Drive
2. Forward Servo
3. Reverse Servo
4. Speed Sensor
5. Thermal Element
6. Valve Body & Solenoids
7. 1-2 Manual Band Servo
8. 1-2 Or 2-3 Accumulator Assemblies

Note. Removal and installation procedures are covered throughout TRANSAXLE DISASSEMBLY and TRANSAXLE REASSEMBLY .

Incorrect Line Pressure

Low fluid level. Thermo element plate pins are misadjusted or out of position. Damaged oil filter. Missing or damaged oil filter seal. Wiring harness is disconnected or damaged. Oil pump assembly components are damaged. Damaged pressure control solenoid. Solenoid "O" ring seals are missing or damaged. Solenoid retainer is missing or damaged. Torque signal regulator valve is binding or damaged. Pressure regulator valve, reverse boost valve, actuator feed limit valve, or low blow-off ball valve is binding or damaged.

Delayed Park-To-Reverse/Drive Engagement

Note. Delayed engagement is any gear engagement which takes longer than 3 seconds when engine is idling, and gear shift lever is moved to "D" or "R" position.

Low fluid level. Low transaxle main line pressure. Damaged or rolled reverse or forward band servo piston oil seal ring. Reverse servo boost valve or forward servo boost valve is binding or damaged. Thermal element not functioning or damaged. TCC blow-off ball is not sealing, causing torque converter drain back. Input clutch assembly components are damaged.

Harsh Park-To-Reverse/Drive Engagement

High transaxle main line pressure. Reverse or forward band servo piston cushion spring broken or missing. No. 5 or No. 6 check ball is out of position or missing. Reverse or forward servo boost valve is binding or damaged. Thermal element is damaged or is not functioning properly.

Slips In Drive Or No Drive

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. Loose or damaged forward band servo oil pipe. Loose 2-1 manual band servo cover or accumulator cover bolts. Missing or damaged 2-1 manual band servo cover gasket. Damaged accumulator cover spacer plate. Forward band servo piston oil seal ring missing or damaged. Servo piston is damaged or is stuck in servo cover. Servo piston cushion spring or retainer is missing or damaged. Servo piston pin is not engaged to forward band. Forward band is worn or burned. Forward band is disengaged from anchor pin. Anchor pin is loose or missing. No. 3 check ball is missing. Torque converter stator clutch is not holding. Drive chain assembly is broken or drive or driven sprockets are damaged. Input clutch assembly components are damaged. 1-2 roller clutch assembly is damaged. Input carrier assembly or reaction carrier assembly components are damaged. Parking pawl assembly is broken or damaged. Sun gear shaft, internal gear assembly or carrier assembly components are damaged.

Slips In Reverse Or No Reverse

Low fluid level. Low transaxle main line pressure. Manual linkage misadjusted. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. Reverse band servo piston oil seal ring is missing or damaged. Servo piston is damaged or is stuck in case bore. Servo piston cushion spring or retainer is missing or damaged. Servo piston pin is not engaged to reverse band. Reverse band is worn or burned. Reverse band is disengaged from anchor pin. Anchor pin is loose or missing. Torque converter stator clutch is not holding. Drive chain assembly is broken or drive and driven sprockets are damaged. Input clutch assembly components are damaged. Reverse reaction drum splines are damaged. Input carrier or reaction carrier assembly components are damaged. Parking pawl assembly is broken or damaged. Sun gear shaft, internal gear assembly or carrier assembly components are damaged.

Locked Up In Drive/Reverse

Manual linkage misadjusted. Input carrier or reaction carrier assembly components are damaged. Parking pawl assembly is broken or damaged. Sun gear shaft, internal gear assembly or carrier assembly components are damaged.

No Park Range

Manual linkage misadjusted. Parking pawl assembly is broken or damaged. Parking pawl actuator is damaged. Actuator guide is damaged or debris is present.

Harsh Or Soft 1-2 Shift Feel

Low fluid level. Low or high transaxle main line pressure. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. 1-2 accumulator is assembled upside down. Damaged or missing 1-2 accumulator piston oil seal ring. Damaged or missing 1-2 accumulator piston cushion spring or outer spring. Stuck or binding 1-2 accumulator piston. Debris in accumulator cover spacer plate passages. Control valve body components are damaged. Damaged 2nd clutch housing oil seal rings, or 4-lobe oil seal rings. 2nd clutch assembly components are damaged.

Harsh Or Soft 2-3/3-2 Shift Feel

Low fluid level. Low or high transaxle main line pressure. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. 2-3 accumulator is assembled upside down. Damaged or missing 2-3 accumulator piston oil seal ring. Damaged or missing 2-3 accumulator piston cushion spring or outer spring. Stuck or binding 2-3 accumulator piston. Debris in accumulator cover spacer plate passages. Control valve body components are damaged. Plugged 3rd clutch oil passage in driven sprocket support assembly. 3rd clutch assembly components are damaged.

Harsh Or Soft 3-4/4-3 Shift Feel

Low fluid level. Low or high transaxle main line pressure. Oil filter is missing, plugged or damaged. Oil filter seal is missing or damaged. 3-4 accumulator is assembled upside down. Damaged or missing 3-4 accumulator piston oil seal ring. Damaged or missing 3-4 accumulator piston outer spring. Stuck or binding 3-4 accumulator piston. Damaged 3-4 accumulator piston cylinder or "O" ring seal. Debris in control valve body or spacer plate passages. Control valve body components are damaged. Missing or damaged 4th clutch orifice. Damaged driven sprocket support assembly. 4th clutch assembly components are damaged.

High Or Low Upshift Or Downshift Speed

Incorrect calibration in PCM. Misadjusted or faulty throttle position sensor.

1st & 2nd Gear Only (2-3 Shift Solenoid Stuck On)

Faulty 2-3 shift solenoid. Debris in control valve body or spacer plate.

1st & 4th Gear Only (1-2 Shift Solenoid Stuck On)

Faulty 1-2 shift solenoid. 3-4 shift solenoid stuck on. Debris in control valve body or spacer plate.

2nd & 3rd Gear Only (1-2 Shift Solenoid Stuck Off)

Faulty 1-2 shift solenoid. 3-4 shift solenoid is stuck off. Missing or damaged shift solenoid "O" ring seal. Plugged or damaged solenoid screen/seal. Debris in control valve body or spacer plate. Stuck, binding or missing actuator feed limit valve.

3rd & 4th Gear Only (2-3 Shift Solenoid Stuck Off)

Faulty 2-3 shift solenoid. Missing or out of position 2-3 shift solenoid and retainer. Missing or damaged shift solenoid "O" ring seal. Plugged or damaged solenoid screen/seal. Debris in control valve body or spacer plate.

1st Gear Only

1-2 shift valve is stuck or binding. Debris in control valve body or spacer plate. Spacer plate and gaskets are assembled incorrect. 2nd clutch assembly components are damaged. Damaged reverse reaction drum splines.

2nd Gear Only

1-2 shift valve is stuck or binding. Debris in control valve body or spacer plate. Input sun gear damaged. Input carrier planetary pinion damaged.

3rd Gear Only

Debris in control valve body or spacer plate. Spacer plate and gaskets are assembled incorrectly.

4th Gear Only

Debris in control valve body or spacer plate. Spacer plate and gaskets are assembled incorrectly.

Slipping Or No 1st Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. Loose or damaged forward band servo oil pipe. Loose 2-1 manual band servo cover or accumulator cover bolts. Missing or damaged 2-1 manual band servo cover gasket. Damaged accumulator cover spacer plate. Forward band servo piston oil seal ring missing or damaged. Servo piston is damaged or is stuck in servo cover. Servo piston cushion spring or retainer is missing or damaged. Servo piston pin is not engaged to forward band. Forward band is worn or burned. Forward band is disengaged from anchor pin. Anchor pin is loose or missing. 1-2 shift valve is stuck or binding. No. 3 check ball is missing. Input clutch assembly components are damaged. 1-2 roller clutch assembly is damaged.

Slipping Or No 2nd Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. 1-2 shift valve is stuck or binding. Debris in passages of control valve body or spacer plate. 2nd clutch housing oil seal rings damaged. Damaged 4-lobe oil seal rings. 2nd clutch housing bushings damaged or worn. 2nd clutch assembly components are damaged.

Slipping Or No 3rd Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. 2-3 shift valve or 3-2 manual downshift valve is stuck or binding. Debris in passages of control valve body or spacer plate. No. 4 or No. 9 check ball is missing or out of position. Plugged 3rd clutch oil passage in driven sprocket support assembly. 3rd clutch assembly components are damaged. 3rd sprag is installed backwards on inner race. Damaged 3rd clutch sprag assembly.

Slipping Or No 4th Gear

Low fluid level. Low transaxle main line pressure. Oil filter missing, plugged or damaged. Oil filter seal missing or damaged. 3-4 shift valve or 4-3 manual downshift valve is stuck or binding. Debris in passages of control valve body or spacer plate. Distortion or damage occurs at manual valve or at case cover, causing oil leak. Plugged 3rd clutch oil passage in driven sprocket support assembly. 4th clutch assembly components are damaged. 3rd sprag is assembled backwards on inner race. Damaged 3rd clutch sprag assembly.

No Engine Braking In Manual 2nd Or Low Range

Loose or damaged 2-1 manual band servo oil pipe. Loose 2-1 manual band servo cover or accumulator cover bolts. Damaged accumulator cover spacer plate. Damaged or missing servo piston seal or servo piston cylinder "O" ring seal. Missing servo exhaust screen, allowing debris into cylinder. Incorrectly assembled 2-1 manual band servo. 2-1 manual band worn or burned. 2-1 manual band is disengaged from anchor pin. Anchor pin is loose or missing.

Converter Clutch Stuck On In All Gears

TCC control valve or TCC regulator apply valve is stuck or binding. Control valve body spacer plate and gaskets are assembled incorrectly or contain incorrect parts. Faulty torque converter. Pressure plate is stuck in applied position.

Converter Clutch Stuck On In 2nd, 3rd & 4th Gear

TCC PWM solenoid valve is stuck on. Control valve body spacer plate and gaskets are assembled incorrectly or contain incorrect parts. PWM internal "O" ring missing or damaged.

Harsh Converter Clutch Apply Or Release

TCC regulator apply valve is stuck or binding, or apply valve spring is missing or damaged. TCC control valve spring is missing or damaged. Control valve body spacer plate and gaskets are assembled incorrect or contain incorrect parts. Faulty torque converter.

Converter Clutch Apply Rough, Slips Or Shudders

TCC regulator apply valve is stuck or binding, or apply valve spring is missing or damaged. Control valve body spacer plate and gaskets are assembled incorrectly or contain incorrect parts. TCC blow-off ball valve or spring is damaged or not sealing. Turbine shaft "O" ring seal is damaged or missing. Turbine shaft oil seal rings are damaged or missing. Turbine shaft is damaged. Turbine shaft bushing is worn or damaged. Faulty torque converter.

No TCC Apply

TCC PWM solenoid is stuck off. TCC control valve or TCC regulator apply valve is stuck or binding. No. 10 check ball is missing or out of position. Control valve body spacer plate and gaskets assembled incorrectly or contain incorrect parts. TCC blow-off ball valve or spring is damaged or not sealing. Turbine shaft "O" ring seal is damaged or missing. Turbine shaft oil seal rings are damaged or missing. Turbine shaft is damaged. Turbine shaft bushing is worn or damaged. Faulty torque converter.

"D" Position (Overdrive)

1. With gearshift lever in "D" position (Overdrive), steadily increase throttle pressure to accelerate vehicle. Using scan tool, monitor throttle position and vehicle speed. Note shift speed engagement points in 2nd gear, 3rd gear and Overdrive. See appropriate shift speed specifications chart as reference for proper shift speeds. Note TCC engagement point while in 3rd gear or 4th gear (Overdrive). (Scheme 32)- (Scheme 35). Ensure proper transaxle model specification is being referenced. see scheme 1 NOTE: Ensure TCC engages in 3rd gear or Overdrive during the following steps. On vehicles with PWM TCC solenoid, TCC engagement point may be difficult to feel. Use scan tool to observe TCC engagement and release points.
2. At vehicle speeds of 40-50 MPH, quickly depress accelerator to half-open position (part-throttle detent downshift). TCC should release, and transaxle should immediately downshift to 3rd gear, 1-2 shift solenoid should turn off and 2-3 shift solenoid should remain off.
3. At vehicle speeds of 40-50 MPH, quickly depress accelerator to wide open position (full-throttle detent downshift). TCC should release, and transaxle should immediately downshift to 2nd gear, 1-2 shift solenoid should remain off and 2-3 shift solenoid should turn on.
4. At vehicle speeds of 40-55 MPH, release accelerator pedal while moving gearshift lever to "3" position (3rd gear). TCC should release, transaxle should downshift into 3rd gear, and engine braking should slow vehicle.
5. Move gearshift lever to "D" position (Overdrive), and accelerate to 40-45 MPH. Release accelerator pedal while moving gearshift lever to "2" position (2nd gear). TCC should release, transaxle should downshift to 2nd gear immediately, and engine braking should slow vehicle.
6. Move gearshift lever to "D" position (Overdrive), and accelerate to 40 MPH. Release accelerator pedal while moving gearshift lever to "1" position (1st gear). TCC should release, transaxle should downshift to 2nd gear and engine braking should slow vehicle. When vehicle speed is 30-40 MPH, transaxle should downshift to 1st gear.
7. With gearshift lever in "D" position (Overdrive), accelerate vehicle to Overdrive with TCC applied. Release accelerator pedal, and lightly apply brakes. TCC should release. Vehicle should downshift to appropriate gear, depending on vehicle speed.

"3" Position (3rd Gear)

With vehicle stopped, move gearshift lever to "3" position (3rd gear) and steadily increase throttle pressure to accelerate vehicle. Note speeds at which vehicle shifts into 2nd and 3rd gears. Note when TCC engages while in 3rd gear.

"2" Position (2nd Gear)

With vehicle stopped, move gearshift lever to "2" position (2nd gear). Accelerate vehicle and note speed at which vehicle shifts from 1st gear to 2nd gear. Accelerate vehicle to 35 MPH. Transaxle should not shift into 3rd gear, and TCC should not engage.

"1" Position (1st Gear)

With vehicle stopped, move gearshift lever to "1" position (1st gear). Accelerate vehicle to 20 MPH. Transaxle should not upshift, and TCC should not engage.

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Stator Check

1. Torque converter stator roller clutch can either remain locked up at all times or freewheel in both directions. If stator is freewheeling at all times, vehicle tends to have poor acceleration from a stop. Vehicle may act normal at speeds greater than 30-35 MPH.
2. If poor acceleration is noted, ensure exhaust system is not blocked, engine timing is correct and transaxle is in 1st gear when starting from stop. If stator is locked up at all times, performance from stop appears normal. Engine RPM and acceleration is limited at high speeds. Engine may overheat from this condition.

HYDRAULIC PRESSURE TESTS

Line Pressure

1. Before performing line pressure test, check fluid level and condition. Check manual control linkage for correct adjustment, and ensure engine is properly tuned.
2. Connect scan tool to vehicle. Start engine and check for DTCs. If DTCs are present, see HYDRA-MATIC 4T65-E ELECTRONIC CONTROLS article. If DTCs are not present, turn engine off. Connect oil pressure gauge to line pressure test port. (Scheme 41)
3. Start engine and allow it to reach normal operating temperature. Using scan tool, access Pressure Control Solenoid (PCS) control test (PC Sol.). Using scan tool, increase pressure control solenoid current in increments of 0.1 amp. Allow pressure to stabilize for 5 seconds after each pressure change.
4. With engine at idle and transaxle in Park, read corresponding line pressure on oil pressure gauge. Compare PCS current reading on scan tool and line pressure reading on gauge. See «PCS CURRENT & LINE PRESSURE SPECIFICATIONS»(ref-11645-S12372002802000112200000) table.
5. If pressure readings are not as specified, attempt diagnosis by symptom. See «SYMPTOM DIAGNOSIS»(ref-11645-S20928953892000112200000) under TROUBLE SHOOTING.

PCS CURRENT & LINE PRESSURE SPECIFICATIONS

Scheme 41

Visual inspection of torque converter may reveal converter is Blue in color from overheating. If torque converter has been removed from vehicle, stator roller clutch can be checked by inserting 2 fingers into splined inner race of roller clutch and attempting to rotate race in both directions. Inner race should rotate freely clockwise but should not rotate or should be difficult to rotate counterclockwise.

End Play Check

Mount Torque Converter End Play Fixture (J-35138) and Dial Gauge (J-8001) on torque converter to check end play. End play should be 0-.020" (0-.50 mm). (Scheme 42)

Scheme 42

Note. See appropriate AUTOMATIC TRANSMISSION REMOVAL article in TRANSMISSION SERVICING.

REVERSE BAND SERVO

1. Remove torque converter and turbine shaft "O" ring seal. Install Holding Fixture (J-28664-B) onto transaxle. (Scheme 43) Install transaxle and holding fixture into Base (J-3289-20). Insert pin into base to hold transaxle in desired position. Using long screwdriver, depress reverse band servo cover by prying against holding fixture. Pry retaining ring from reverse band servo cover. (Scheme 44)
2. Remove screwdriver. Servo assembly will push servo cover up. Using small screwdriver, pull servo cover "O" ring seal out through slot in case. Cut servo "O" ring seal. Depress reverse band servo cover. Grasp one end of cut seal and pull from servo cover. Servo assembly will push servo cover up. Remove servo cover, reverse band servo assembly and reverse band servo piston return spring.

Scheme 43

FORWARD BAND SERVO

Position transaxle with oil pan facing up. Using long screwdriver, depress forward band servo assembly cover by prying against work bench. Hold servo assembly and remove forward band servo cover bolts. (Scheme 44) Remove screwdriver. Servo assembly will push servo cover out. If cover does not move, tap cover with rubber mallet. Remove servo cover and cover seal. Remove servo assembly. Remove piston return spring from forward band servo.

OIL PAN & FILTER

Remove oil pan bolts. Remove oil pan and gasket. Using screwdriver, pry oil filter out of case. Pry oil filter seal out of case. DO NOT damage case sealing surface. (Scheme 44) Inspect oil pan magnet for steel particles. Excessive amounts of steel shavings indicates internal transaxle damage. Using screwdriver, pry metal crimping away from top of oil filter and pull oil filter apart. Inspect oil filter for clutch plate friction material, steel particles and Bronze slivers, indicating bushing damage or internal transaxle damage.

Scheme 44

CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR

1. Position transaxle with control valve body cover facing up. Remove case side cover (control valve body cover) bolts. (Scheme 45) Remove cover and gaskets. Using small screwdriver, pry wiring harness electrical connectors off transaxle fluid pressure manual valve position switch, 1-2 and 3-4 shift solenoid, 2-3 shift solenoid, TCC PWM solenoid, pressure control solenoid and input speed sensor. Gently pull transaxle fluid temperature sensor from clip. (Scheme 46)
2. Lift wiring harness assembly off transaxle. Remove oil pump assembly bolts. DO NOT remove No. 1 oil pump cover bolt at this time. (Scheme 47) Remove wiring harness clip. Lift oil pump assembly off control valve body. Set oil pump assembly on its cover.
3. Remove control valve body bolts. (Scheme 48) Manual valve position switch is very delicate, use care when handling. Carefully lift manual valve position switch assembly off control valve body. Remove control valve body. Remove 2 bolts retaining spacer plate and gaskets to valve body. Remove spacer plate with 2 screen/seal assemblies and gaskets from valve body. Remove 6 check balls from valve body. (Scheme 50) Remove case cover pin. Remove 4 check balls from case cover. (Scheme 49)
4. Remove oil pump drive shaft from case cover. Position transaxle so Vehicle Speed Sensor (VSS) is facing up. Remove VSS bolt and VSS. (Scheme 44)

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

OUTPUT SHAFT

1. Remove case extension bolts. Remove case extension and extension seal. (Scheme 44) Leave front differential carrier thrust washer and bearing on carrier. Rotate differential carrier until differential carrier pinion shaft is in horizontal position.
2. Place Axle Remover Wedge (J 42562) between end of output shaft and differential pinion shaft. Using hammer, strike axle removal wedge to compress snap ring and push output shaft from differential side gear. (Scheme 51) Remove output shaft assembly. Remove snap ring from output shaft.

Scheme 51

FRONT DIFFERENTIAL CARRIER END PLAY CHECK

1. Ensure thrust washer and bearing are on front differential carrier. Install case extension seal onto case extension, if removed. Install case extension onto transaxle. Install 2 case extension bolts. DO NOT tighten bolts to specification. Only tighten bolts until case extension is fully seated.
2. Position transaxle with case extension facing up. Install Aligning Tool (J-26958) and dial indicator. (Scheme 52) Zero dial indicator. Use Snap Ring Remover (J-28585) or large screwdriver to lift front differential carrier. Pry up on VSS reluctor wheel through sensor hole in case extension.
3. Note dial indicator measurement. End play should be.005-.025" (.13-.64 mm). Record measurement for reassembly reference. If dial indicator reading is less than.005" (.13 mm), install next smaller size thrust washer, and check end play. If dial indicator reading is more than.025" (.64 mm), install next larger size thrust washer, and check end play. For available thrust washer sizes, see «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(ref-11645-S35016282162000112200000) table under TRANSAXLE REASSEMBLY.

Scheme 52

MANUAL VALVE LINK & OIL DAM

1. Remove manual shift detent bolt and manual shift detent. Compress manual valve link spring. Lift link off manual valve. (Scheme 53)
2. Position manual valve so valve will not interfere with case cover removal. Remove oil dam from case. (Scheme 44) Using small screwdriver, pry input speed sensor clip out of case cover. Use care when handling speed sensor. Carefully pull input speed sensor out of case cover.

Scheme 53

CASE COVER & GASKETS

Remove indicated case cover bolts. (Scheme 54) Hold manual valve in place. Lift case cover off case. Remove upper and lower case cover gaskets. see scheme 59

Scheme 54

4TH CLUTCH SHAFT & PLATES

Remove 4th clutch backing plate, composition plates and steel plates. Remove 4th clutch shaft. (Scheme 55) Remove drive chain lube scoop. (Scheme 59)

Scheme 55

Drive Chain (Drive Link) Stretch Check

Ensure driven sprocket support assembly and both sprockets are fully seated. Pull drive chain toward case at indicated location. see scheme 32 Measure distance between case and drive chain. If measurement is.126" (3.2 mm) or more, drive chain may be reused. If measurement is less than.126" (3.2 mm), replace drive chain.

REVERSE BAND & REACTION DRUM

Tilt band in order to disengage band from anchor pin in case. Remove reverse band. Lift reverse reaction drum from transaxle case.

INPUT CLUTCH HOUSING END PLAY CHECK

1. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer to lift input clutch housing. see scheme 35 Install input clutch housing assembly into case. Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input clutch housing.
2. Remove remover/installer from input clutch housing. Install case extension with Output Shaft Loading/Aligning Tool (J-26958), Adapter Plug (J-26958-10) and Loading Tool Adapter (J-43425) attached to case extension. (Scheme 56) Using 2 bolts, install End Play Gauge (J-33386) onto case. (Scheme 57) Tighten bolts to securely hold gauge. Tighten aligning tool finger tight in order to eliminate differential carrier end play. (Scheme 56)
3. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge, measure end play between end play gauge and thrust washer.
4. Record measurement for proper end play clearance during reassembly. End play should be 0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during transaxle reassembly. If end play is greater than.006" (.15 mm), select next size larger thrust washer and recheck. For input clutch thrust washer identification, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(ref-11645-S10486469282000112200000) table under TRANSAXLE REASSEMBLY.
5. Remove end play gauge. Install remover/installer into input clutch housing. Lift input clutch housing from case. Remove aligning tool, adapter plug and loading tool adapter from case extension.

Scheme 56

Scheme 57

CASE EXTENSION & DIFFERENTIAL CARRIER

Remove case extension bolts. Remove case extension and remove seal. (Scheme 44) Remove differential carrier thrust washer and thrust bearing. (Scheme 58) Remove differential carrier assembly. Remove differential sun gear shaft. Remove thrust bearing from differential carrier sun gear. Bearing may be stuck to carrier assembly. Remove differential carrier (final drive) sun gear. Remove parking gear. Remove thrust bearing from differential carrier internal gear. (Scheme 58)

INPUT & REACTION CARRIER

Position transaxle with case cover facing up. Remove input carrier assembly. Remove input carrier and reaction carrier lube dam. Lube dam may be stuck to input carrier assembly. Remove thrust bearing from reaction carrier. Remove reaction carrier assembly. (Scheme 58)

REACTION SUN GEAR & 2-1 MANUAL BAND

Remove thrust bearing from reaction sun gear. Remove reaction sun gear assembly. Tilt band to disengage 2-1 manual band assembly from anchor pin. Remove 2-1 manual band from case. (Scheme 58)

1-2 SUPPORT DRUM & FORWARD BAND

Install Support Remover/Installer (J-38358) onto 1-2 support drum assembly. Lift remover/installer with 1-2 support drum out of case. Tilt band to disengage band from anchor pin. Remove forward band from case. (Scheme 58)

FINAL DRIVE INTERNAL GEAR

Remove thrust washer from final drive internal gear. Use snap ring remover or large screwdriver to remove final drive internal gear retaining ring. Lift final drive internal gear out of case by depressing parking pawl to clear case. (Scheme 58)

PARKING SYSTEM COMPONENTS

1. Using side cutting pliers, remove manual shift shaft pin. DO NOT cut through pin. Protect case with piece of wood or rubber under pliers when removing pin. Remove manual valve link and spring from manual shift detent lever. Remove manual shift detent lever nut from manual shift shaft. Remove manual shift detent lever and remove parking pawl actuator. (Scheme 60)
2. Position transaxle with reverse band servo bore facing up. Pull manual shift shaft out of case. Using small screwdriver, pry manual shift shaft seal from case. Remove parking pawl actuator guide pin. Remove parking pawl actuator guide from case. Remove actuator guide seal from guide. (Scheme 60)

Scheme 58

Scheme 59

Scheme 60

VEHICLE SPEED SENSOR RELUCTOR WHEEL

Note. DO NOT remove reluctor wheel if reluctor wheel is not damaged.

Functional Check

Position 1-2 support drum on bench. Install reaction sun gear assembly into 1-2 support drum. Rotate reaction sun gear counterclockwise. Rotate 1-2 support drum clockwise. (Scheme 62) Roller clutch should move freely in indicated directions. Roller clutch should lock in opposite direction. If roller clutch does not function as described, clutch is not assembled correctly. Reassemble as necessary.

Scheme 61

Scheme 62

Input & 3rd Sprag Clutches Functional Check

Hold input sun gear stationary. 3rd sprag clutch outer race should rotate only in counterclockwise direction and not in clockwise direction. Input sprag clutch outer race should rotate in clockwise direction and not in counterclockwise direction. (Scheme 66)

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Input Clutch & 3rd Clutch Functional Check

Using rubber tipped air nozzle, apply a maximum of 20 psi (1.4 kg/cm 2 ) at indicated fluid passage holes. (Scheme 68) Ensure input clutch and 3rd clutch apply. If clutch does not apply, recheck component reassembly.

Scheme 67

Scheme 68

INPUT CLUTCH HOUSING CHECK BALL VALVE

Note. Remove check ball valve only if inspection or leak check indicates problem with check ball valve.

2nd & 4th Clutch Functional Check

1. Apply 20 psi (138 kPa) of compressed air to feed holes marked 2 and 4, and listen for 2nd and 4th clutch application. (Scheme 71) Hold pressure for 5 seconds. If clutches do not apply and hold, disassemble driven sprocket support components.
2. Inspect all seals and clutches for proper assembly. Reassemble and repeat functional check. When clutches apply and hold correctly, remove driven sprocket support assembly and 2nd clutch housing thrust washer from 2nd clutch housing assembly.

Scheme 69

Scheme 70

Scheme 71

DRIVE SPROCKET & TURBINE SHAFT

Note. DO NOT damage grooves under oil seal rings.

CASE COVER COMPONENTS

Note. DO NOT remove any bore plugs unless inspection indicates replacement is necessary.

Note. DO NOT use any type of adhesive or sealer when assembling gaskets. Petroleum jelly may be used during assembly.

CASE SIDE COVER

Note. Case side cover gasket and channel plate seal may be reused if not damaged.