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

ACCUMULATOR ASSEMBLY & 2-1 MANUAL BAND SERVO

1. Remove accumulator cover bolts from 1-2 and 2-3 accumulator cover. (Scheme 14) Remove bolts from 2-1 manual band servo cover. Using screwdriver, gently pry lube oil pipe retainer from case. Remove lube oil pipe from front differential carrier internal gear lube hole. (Scheme 15)
2. Remove 1-2 and 2-3 accumulator assembly and 2-1 manual band servo assembly together. Remove pipe assembly. DO NOT twist pipe assembly. Remove cover gasket from 2-1 manual band servo.

Scheme 14

Scheme 15

Drive & Driven Sprocket Disassembly

1. Remove 4th clutch shaft thrust washer. Remove drive sprocket thrust washer. Washer may be stuck to case cover. Remove VSS reluctor wheel. Note location of master link on drive chain. Link is different color than other links and may be facing up or down toward case.
2. Lift drive and driven sprockets with drive chain out of case. Lift both sides evenly. It may be necessary to tap turbine shaft up gently with a rubber mallet. Remove drive and driven sprocket thrust washers. see scheme 31and (Scheme 17). Thrust washers may be stuck to sprockets.

Scheme 16

Scheme 17

DRIVE SPROCKET SUPPORT ASSEMBLY

Insert 2 case cover bolts into driven sprocket support assembly. (Scheme 18) Grasp bolts and lift support assembly. Remove thrust washer from 2nd clutch housing. Washer may be stuck to support assembly.

Scheme 18

INPUT & 2ND CLUTCH ASSEMBLIES

1. Adjust collar on Final Drive/Clutch Remover/Installer (J-33381-A) to ensure threaded rod is fully loosened. Install Remover/Installer into 2nd clutch housing assembly. Tighten threaded rod until rod is finger tight. Lift up on remover/installer with 2nd clutch and input clutch assemblies attached. Sprag clutch assemblies will also be attached. (Scheme 19)
2. Place complete assembly on bench. Loosen threaded rod and remove remover/installer. Lift 2nd clutch housing assembly off input clutch housing. Remove input clutch housing thrust bearing from input housing. Remove selective thrust washer from input clutch housing. see scheme 39

Scheme 19

INPUT SPRAG, SUN GEARS & 3RD ROLLER CLUTCH ASSEMBLIES

Remove input clutch sprag assembly, 3rd roller clutch assembly and input sun gear. Remove reverse reaction drum, input carrier assembly and thrust bearing. see scheme 38

Disassembly & Reassembly

If vent is damaged, use pliers and pry bar to remove vent. Use hammer and punch to install vent. If oil pressure test hole plug was removed, install plug and tighten to specification. See TORQUE SPECIFICATIONS .

If damage is visible, use slide hammer and bearing puller to remove bearing from drive sprocket support. Remove drive sprocket support bolts and remove drive sprocket. Install NEW bearing using drive handle and bearing installer. (Scheme 20) Install NEW drive sprocket support. Install and tighten drive sprocket support bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 20

Disassembly

1. Using screwdriver remove retaining ring from front differential carrier. Remove planetary pinion gear pin, thrust washers, roller bearings, spacer and pinion gear. see scheme 38 Remove remaining planetary pinions in same manner. Remove differential carrier sun gear thrust bearing.
2. Place final drive carrier components into oil pan to ensure roller bearings are not lost. Using drift pin and hammer remove differential pinion shaft retaining pin. Remove differential pinion shaft, gears, pinion gear thrust washers, side gears and Bronze side gear thrust washers. see scheme 38

Reassembly

1. Assemble differential side gears and thrust washers into carrier. Using petroleum jelly, stick thrust washers onto pinion gears. Assemble pinion gears and thrust washers into differential carrier. (Scheme 22) Rotate gears into position. Slide differential pinion shaft into carrier through pinion gears. Align holes in pinion shaft retaining pin to hole in carrier housing. Using drift pin and hammer, install pinion shaft retaining pin into carrier.
2. Apply petroleum jelly to inside of differential carrier planetary pinion gear. For each planetary pinion gear, insert roller bearing spacer onto pin. Spacer must be inserted between 2 rows of roller bearings. Install roller bearings into gear one at a time. Differential ratio of 2.86:1 or 2.84:1 has 2 rows of 18 rollers. All other gear ratios have 2 rows of 22 rollers.
3. Install differential carrier sun gear thrust bearing into carrier housing. Remove planetary pinion gear pin from its pinion gear. DO NOT move rollers out of position. Attach 2 pinion gear thrust washers on each side of pinion gear. Ensure position of pinion gears in housing is same as when disassembled. Install pinion gear assemblies into carrier housing. Install planetary pinion gear pins. Install retaining ring over planetary pinion gear pins.

Scheme 21

Scheme 22

To remove reluctor wheel, install flat metal stock over output shaft opening. Position Bearing Remover (J-22888) arms onto outer edges of reluctor wheel. Position bearing remover shaft onto flat metal stock. Pull wheel off of carrier. To reassemble, heat reluctor wheel slightly. Using plastic hammer, install reluctor wheel onto carrier by tapping evenly around reluctor wheel edge. see scheme 38

Using small screwdriver, gently pry thrust bearing off of 1-2 support drum. Lift 1-2 support roller clutch assembly out of 1-2 support drum. see scheme 38

Install 1-2 roller clutch assembly into 1-2 support drum. Note position of cage assembly to inner race. see scheme 44 Install thrust bearing onto 1-2 support drum. Press down with hand pressure only.

1. Remove input and 3rd sprag clutch assemblies from input clutch housing. see scheme 38and see scheme 39. Remove and discard spiral lock retaining ring from outer race retainer of clutch sprag. Remove 3rd clutch sprag and input clutch sprag assemblies from inner race and retainer. Remove inner race and retainer. Remove input sun gear spacer from input sun gear. see scheme 38
2. Remove 3rd clutch sprag retainer. Remove end bearing and center bearing from sprag outer races. DO NOT disassemble sprag components. Remove sprag components from outer races.

1. Position input clutch sprag outer race on flat surface with flat side facing down. Insert end bearing for input and 3rd clutch sprag into outer race. Insert input sprag into outer race. see scheme 48
2. Position 3rd clutch sprag outer race on flat surface with beveled side facing down. Install center bearing into 3rd clutch. Install 3rd sprag into 3rd clutch outer race. Lip on sprag cage must be facing up. Insert input and third clutch sprag end bearing into third clutch sprag outer race with flat side up. see scheme 49
3. Install input clutch sprag assembly onto input and third clutch sprag inner race with flat side of input clutch sprag outer race facing down. Install third clutch sprag assembly onto input and third clutch sprag inner race with beveled side of third clutch sprag outer race facing input clutch sprag assembly.
4. Attach retaining ring installer to arbor press. Using press and small flat blade screwdriver, install retaining ring onto input clutch sprag. Assemble spacer onto input sun gear. Install input and 3rd sprag clutch assemblies onto input sun gear. see scheme 50

1. Using flat-blade screwdriver, remove retaining ring from input clutch housing. Remove input clutch backing plate. Remove all input clutch plate assemblies. Remove input clutch waved plate and input clutch apply plate.
2. Using flat-bladed screwdriver, remove retaining ring from input clutch housing. Remove 3rd clutch backing plate. Remove 3rd clutch plate assembly. Remove 3rd clutch waved plate. Remove input shaft thrust bearing. see scheme 39
3. Using spring compressor and adapter, compress 3rd clutch spring assembly. Using snap ring pliers, remove retaining ring from input clutch housing. DO NOT over expand retaining ring during removal. Remove adapter, spring compressor and 3rd clutch spring assembly. Remove 3rd clutch piston and seal.
4. Using spring compressor, compress input clutch spring and retainer assembly. Using snap ring pliers, remove retaining ring from input clutch housing. DO NOT over expand retaining ring during removal. Remove spring compressor. Remove 3rd clutch piston housing, spring assembly and input clutch piston. see scheme 39
5. Remove 3rd clutch piston inner seal, 3rd clutch housing "O" ring seal and input clutch piston inner seal. Cut and remove input shaft oil seal rings. DO NOT damage grooves on shaft when oil seal ring is removed.

1. Lubricate NEW input clutch piston inner seal with ATF. Using appropriate piston seal protector, install input clutch piston inner seal onto input clutch housing. Install NEW "O" ring seal in input clutch housing. Lubricate NEW 3rd clutch piston inner seal with ATF. Using appropriate piston seal protector, install 3rd clutch piston inner seal onto input clutch housing.
2. Lubricate NEW input clutch piston outer seal with ATF, install seal onto piston. Install input clutch piston into input clutch housing. Install input clutch spring and retainer into input clutch housing. Install 3rd clutch piston housing into input clutch housing. Using spring compressor and snap ring pliers, install retaining ring in 3rd clutch housing. see scheme 39 Remove spring compressor.
3. Lubricate NEW 3rd clutch piston assembly and install into input housing. Install 3rd clutch spring assembly into input housing. Using spring compressor, adapter and snap ring pliers, install 3rd clutch housing retaining ring. Insert 3rd clutch waved plate into input housing.
4. Install first external splined plate with steel side against waved plate. Place composition side of all plates facing up. Install 3rd clutch plates into input housing. Start by inserting a steel 3rd clutch plate with external splines. Alternate with internal splined plates. Install 3rd clutch backing plate with UP marking facing up. Install retaining ring into input housing.
5. Install input clutch apply plate into input housing with notched side of teeth facing downward against retaining ring on 3rd clutch backing plate. Install input clutch waved plate. Start with first input clutch steel plate. Assemble composition plates alternately between steel plates. Install input clutch backing plate with tapered teeth side facing up. Install retaining ring on input clutch housing. Install input shaft thrust bearing into input clutch housing. see scheme 52

Using 1/4" drift and hammer, remove check ball valve from input clutch housing. To reassemble, use 3/8" drift and hammer to install check ball valve into input clutch housing. (Scheme 23)

Scheme 23

Using small screwdriver, align teeth of input clutch plate assembly with 3rd clutch plate assembly. Ensure sprag assembly is fully seated into housing. Insert combined input sprag clutch and 3rd sprag clutch assembly into input clutch housing assembly.

Using flat-blade screwdriver, remove retaining ring from 2nd clutch housing. Remove backing plate. see scheme 39 Remove composition plates, steel plates and apply plate. Remove waved plate. Remove retaining ring. Remove 2nd clutch spring assembly and 2nd clutch piston.

1. Install Adapter (J-41992-3) into NEW 2nd clutch piston. Install piston and adapter into Protector (J-41992-1). Install piston assembly into 2nd clutch housing. Center inner seal protector onto hub by pressing down on center of protector. Install Piston Installer (J-41992-2) onto protector. Legs of installer go into slots of protector. Use hand pressure to press down on installer until piston is seated.
2. Install 2nd clutch spring assembly into housing. Install retaining ring. Install waved plate. Install apply plate into 2nd clutch housing with DN or DOWN marking toward piston. Install composition plates and steel plates, starting with composition plate and alternating each plate. Install backing plate and retaining ring. see scheme 39

If check ball valve does not leak, DO NOT replace check ball valve. Remove check ball valve from housing using 1/4" drift and hammer. Tap in NEW check ball assembly using same drift and hammer.

Using appropriate spring compressor, compress 4th clutch spring assembly. Remove snap ring from driven sprocket support assembly. see scheme 56 Remove spring compressor, spring assembly and 4th clutch piston from driven sprocket support assembly. Remove outer seal from piston. Remove inner seal from driven sprocket support assembly hub. Remove oil seal rings and 4-lobed ring seal from driven sprocket support assembly. see scheme 39

1. Lubricate NEW inner and outer seal with ATF prior to installation. Install outer seal on 4th clutch piston. Install inner seal for 4th clutch piston onto driven sprocket support hub. see scheme 57
2. Install 4th clutch piston into driven sprocket support and align components. Install 4th clutch spring assembly into piston. Using spring compressor, compress spring assembly and install snap ring. see scheme 56 Lubricate NEW oil seal rings for 2nd clutch housing if being replaced. Install rings onto driven sprocket support hub.

Using appropriate bearing remover and hammer, drive driven sprocket support bearing from support. To reassemble, position driven sprocket support bearing assembly so markings on edge are facing up. Using appropriate bearing installer and hammer, seat bearing flush to or below support hub.

1. Install sprag clutches into input housing. Ensure selective thrust washer and thrust bearing assembly for input clutch housing are in place. Using small screwdriver, align 2nd clutch teeth. Install 2nd clutch housing assembly onto 2nd clutch hub of input clutch housing assembly. see scheme 39
2. Install Final Drive/Clutch Remover/Installer (J-33381-A) into 2nd and input clutch housings. (Scheme 19) Tighten threaded rod until rod is finger tight.

Cut oil seal rings from turbine shaft. Remove oil seal rings. Remove drive sprocket retaining ring. Remove drive sprocket from turbine shaft. see scheme 31

1. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. Assemble drive and driven sprockets into drive chain assembly as follows: If old drive chain is being reinstalled, assemble drive chain and sprockets with master link (Bronze) facing in same direction as removed. See «DRIVE & DRIVEN SPROCKETS»(ref-11645-S16139194982000112200000) under TRANSAXLE DISASSEMBLY. If NEW drive chain assembly is being installed, assemble drive chain and sprockets with master link facing upward.
2. Install drive chain assembly and sprockets into case. Slight rocking motion may be required to work sprockets into place. Install input speed sensor reluctor wheel onto drive sprocket. Install 4th clutch shaft thrust washer onto driven sprocket. see scheme 31 Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See «DRIVE & DRIVEN SPROCKETS»(ref-11645-S16139194982000112200000) under TRANSAXLE DISASSEMBLY.

Remove manual valve. Remove cylinder and "O" ring seal for 3-4 accumulator piston. Remove outer and inner spring. Remove pin for 3-4 accumulator piston. (Scheme 24)

Install NEW seal onto 3-4 accumulator piston. Install 3-4 accumulator piston into case cover. Insert 3-4 accumulator piston pin through front of case cover and into piston. Install NEW seal onto accumulator piston cylinder. Install springs into 3-4 accumulator piston cylinder. Using slight twisting motion, insert accumulator piston cylinder into case cover. Assemble manual valve and install valve assembly into case cover.

Scheme 24

Using Seal Remover (J-23129) and slide hammer, remove left oil seal from case cover, or right oil seal from case extension. To install, use appropriate seal installer and hammer. Lubricate oil seal lip with transaxle fluid. Ensure seal was not damaged during installation.

Install upper and lower gaskets for transaxle case cover. (Scheme 24) Ensure manual valve is held in place and assemble case cover onto pins in case. Finger tighten all transaxle case cover bolts. See CASE COVER BOLT SPECIFICATIONS table under TRANSAXLE REASSEMBLY. Tighten case cover bolts to specification. See TORQUE SPECIFICATIONS. DO NOT use an impact wrench to tighten bolts.

Thoroughly clean and air dry control valve body. Remove each valve train, noting location of each component. Some valves are under spring pressure, cover bores when removing retainers. Remove retainers with small screwdriver. Lay valves, springs and bushings on clean surface in order removed. (Scheme 25)and (Scheme 26).

To reassemble valve body components, reverse disassembly procedure. Ensure all components are installed in original locations.

Scheme 25

Scheme 26

Clean and air dry oil pump. Remove oil pump cover bolts. Remove oil pump cover. Remove vane rings, vanes and rotor. Remove oil seal ring and slide "O" ring seal. Remove outer and inner oil pump prime springs. Remove slide, slide seal support and slide seal. Remove pivot pin. Remove outlet screen. see scheme 64

Install oil pump outlet screen. Install vane rings onto pump pocket. Install pump slide into pump body. Install seal and support into slide. Install inner priming spring into outer priming spring. Install both springs into pump body. Install "O" ring and seal ring onto slide. see scheme 64 Install rotor into pump body. Install vanes into rotor slots, ensuring vanes are flush with top of rotor. Install pump cover onto body using cover bolts to specification. Tighten bolts. See TORQUE SPECIFICATIONS.

Remove servo piston cylinder from servo cover. Remove "O" ring seal from servo piston cylinder. Remove piston assembly, servo piston spring and servo exhaust screen from cylinder. Remove servo piston seal from piston. Using small screwdriver, remove retaining ring from servo piston pin. Remove servo piston, cushion spring and spring retainer from servo piston pin. (Scheme 15)

1. Remove accumulator cover bolts from accumulator assembly. Remove accumulator cover and spacer plate from accumulator housing. Disassemble 1-2 and 2-3 accumulator pistons, piston pins, inner and outer springs and cushion springs from accumulator housing. (Scheme 15) Remove piston oil seal rings from 1-2 and 2-3 accumulator pistons.
2. Disassemble 2-1 manual band servo and forward band servo oil pipes, lube oil pipe assembly from accumulator cover, and 2-1 manual band servo cover. Disassemble lube oil pipe, hose clamps, oil hose, lube oil pipe retainer and lube oil pipe with washer. (Scheme 15)

1. Install piston oil seal rings onto 1-2 and 2-3 accumulator pistons. Lubricate oil seal ring with transaxle fluid. Assemble 1-2 and 2-3 piston pins and pistons. Assemble 1-2 and 2-3 accumulator piston springs and piston assembly into accumulator housing. (Scheme 15)
2. Assemble accumulator spacer plate and cover onto accumulator housing. Install accumulator bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000). Assemble lube oil pipe, oil hose, hose clamps, pipe retainer and pipe with washer. (Scheme 15)
3. Assemble 2-1 manual band servo and forward band servo oil pipes into accumulator assembly. Assemble 2-1 manual band servo and forward band servo oil pipes into 2-1 manual band servo cover. Install lube oil pipe assembly into accumulator assembly.

Dissemble servo piston spring from servo assembly. Remove servo piston oil seal ring from servo piston. Remove servo pin retaining ring from servo piston pin. Disassemble servo piston, servo piston cushion spring, retainer and servo piston pin. see scheme 18

Disassemble reverse band servo piston from servo assembly. Remove servo piston oil seal ring from servo piston. Remove servo pin retaining ring from servo piston pin. Disassemble servo piston, servo piston cushion spring, retainer and servo piston pin.

TRANSAXLE REASSEMBLY

Note. End play checks performed during TRANSAXLE DISASSEMBLY procedure must be rechecked at appropriate reassembly stage. For thrust washer, thrust bearing, bushing and seal installation direction and location during reassembly, refer to appropriate illustration. (Scheme 27)- (Scheme 31).

1. Install shift and park linkage components into case. Install final drive internal gear assembly into case. Align parking pawl with parking pawl actuator. Using snap ring remover or long screwdriver, install retaining ring into case. see scheme 38
2. Position transaxle with oil pan flange facing down. Ensure sun gear thrust bearing is installed into differential carrier. Install differential carrier sun gear. Step in sun gear must be pointing toward parking gear. Install parking gear. Install internal gear thrust bearing into differential carrier. Ensure bearing is positioned properly. Install sun gear shaft into differential carrier. (Scheme 22) Install differential carrier into case.
3. Install selective thrust washer and thrust bearing onto differential carrier. Install seal onto case extension. Install case extension onto transaxle case. Install and tighten 2 case extension bolts only until case extension is seated into case. DO NOT torque bolts.
4. Position transaxle case with flange for case cover facing up. Install differential carrier internal gear thrust washer into case. Install forward band into case. Locate band onto forward band anchor pin. Position band apply pin in case opening.
5. Install 1-2 support drum. Position 2-1 band on anchor pin. Install reaction sun gear and drum. Ensure sun gear and drum fully engage 1-2 support roller clutch. Check roller clutch for correct operation. see scheme 45
6. Install reaction carrier/sun gear thrust bearing onto reaction carrier. Install reaction carrier into transaxle case and rotate carrier so pinions engage reaction sun gear. Install thrust bearing and lube dam onto input carrier. Install input carrier into transaxle case and rotate carrier so pinions engage reaction carrier internal gear. see scheme 47
7. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates. Install input clutch roller clutch and sprag assemblies into case using Final Drive/Clutch Installer (J-33381). DO NOT install 2nd clutch housing, thrust bearing or thrust washer at this time.
8. Check input clutch housing end play. See «INPUT CLUTCH HOUSING END PLAY CHECK»(ref-11645-S24907976282000112200000) under TRANSAXLE DISASSEMBLY. Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be.0-.006" (.0-.15 mm). If clearance is not as specified, use different thrust washer. See «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(ref-11645-S10486469282000112200000) table. Remove input clutch assembly. INPUT CLUTCH THRUST WASHER IDENTIFICATION Washer ID No. Color Thickness - In. (mm) 1 Orange/Green.114-.118 (2.90-3.00) 2 Orange/Black.120-.124 (3.05-3.15) 3 No Color.126-.130 (3.20-3.30) 4 White.132-.136 (3.35-3.45) 5 Blue.138-.142 (3.50-3.60) 6 Pink.144-.148 (3.65-3.75) 7 Brown.150-.154 (3.80-3.90) 8 Green.156-.159 (3.95-4.05) 9 Black.161-.165 (4.10-4.20) 10 Purple.167-.171 (4.25-4.35) 11 Purple/White.173-.177 (4.40-4.50)
9. 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) has splines with 10 degree sides.
10. Install reverse band into case, locating band on anchor pins. Install selective thrust washer and thrust bearing onto input clutch assembly. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub.
11. Install final drive/clutch installer into assembled input and second clutch housing assemblies. Tighten threaded rod of final drive/clutch installer until rod is finger tight. Using final drive/clutch installer, lift input and second clutch housing assembly, and install input and second clutch housing assembly into case. (Scheme 19) Ensure input clutch housing assembly is fully seated. Ensure second clutch housing is.500" (13 mm) above top of reverse band assembly.
12. Install thrust washer onto driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case. (Scheme 18) Ensure support is flush with or below case.
13. Use petroleum jelly to hold thrust washer onto drive and driven sprockets. Assemble drive and driven sprockets into drive chain assembly as follows: If old drive chain is being reinstalled, assemble drive chain and sprockets with master link (Bronze) facing in same direction as removed. See «DRIVE & DRIVEN SPROCKETS»(ref-11645-S16139194982000112200000) under TRANSAXLE DISASSEMBLY. If NEW drive chain assembly is being installed, assemble drive chain and sprockets with master link facing upward.
14. Install drive chain assembly and sprockets into case. Using slight rocking motion, may be required to work sprockets into place. Install input speed sensor reluctor wheel onto drive sprocket. (Scheme 17) Perform DRIVE CHAIN (DRIVE LINK) STRETCH CHECK. See «DRIVE & DRIVEN SPROCKETS»(ref-11645-S16139194982000112200000) under TRANSAXLE DISASSEMBLY.
15. Install 4th clutch shaft thrust washer onto driven sprocket. Insert 4th clutch shaft into transaxle case through driven sprocket. see scheme 31 Shaft must fully seat into input sun gear. Install drive chain lube scoop into case.
16. Install fourth clutch apply plate over fourth clutch shaft assembly and into driven sprocket support with machined side towards driven sprocket. Install remaining 4th clutch plates, starting with composition plate and alternating with steel plates. Clutch plates should align in driven sprocket support.
17. If necessary, pry out axle seal from case cover, and tap NEW seal into place. Install pistons and pins into case cover. Install springs into case cover. Install case cover gaskets. Install 4th clutch shaft and drive sprocket thrust washers onto case cover. (Scheme 24)
18. Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch plates. see scheme 31 Install case cover bolts. See «CASE COVER BOLT SPECIFICATIONS»(ref-11645-S18217872682001042500000). Tighten case cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000). Install oil pump drive shaft. CASE COVER BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 1.3 (32) 2 0.24 (6) 1.6 (40) 3 0.31 (8) 2.0 (50) 4 0.24 (6) 1.2 (30) (1) For bolt location, refer to illustration. see scheme 30
19. Install drive link lube scoop into case. see scheme 39 Connect manual valve link to manual valve. see scheme 29 Install manual shift detent, and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).
20. 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. see scheme 63
21. 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
22. 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.
23. Install control valve body bolts. See «VALVE BODY BOLT SPECIFICATIONS»(ref-11645-S07883515462001042500000) table. Finger tighten bolts to prevent cross-threading. Tighten bolts in a spiral pattern starting with bolts at center of control valve body. If bolts are tightened at random, valve bores may become distorted and prevent proper valve operation. Tighten valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).
24. Install oil pump assembly onto control valve body. Install oil pump bolts in specified locations. See «OIL PUMP BOLT SPECIFICATIONS»(ref-11645-S05440018712001042500000) table. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000). Install electronic components and wiring harness. Ensure wire connectors are installed in correct locations. see scheme 22 VALVE BODY BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 2.6 (65) 2 0.24 (6) 2.4 (60) 3 0.24 (6) 1.2 (30) 4 0.24 (6) 1.8 (45) 5 0.24 (6) 2.2 (55) 6 0.24 (6) 3.7 (95) 7 0.31 (8) 3.5 (90) 8 0.24 (6) 0.8 (20) 9 0.24 (6) 3.3 (85) (1) For bolt location, refer to illustration. see scheme 24 OIL PUMP BOLT SPECIFICATIONS Bolt No. (1) Diameter - In. (mm) Length - In. (mm) 1 0.24 (6) 0.8 (20) 2 0.24 (6) 3.7 (95) 3 0.24 (6) 3.3 (85) (1) For bolt location, refer to illustration. see scheme 23
25. Check front differential carrier end play. See «FRONT DIFFERENTIAL CARRIER END PLAY CHECK»(ref-11645-S25926083712000112200000) under TRANSAXLE DISASSEMBLY. Install appropriate thrust washer on to input shaft and hold in position with petroleum jelly. See «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(ref-11645-S35016282162000112200000) table. Install output shaft. Ensure output shaft snap ring locks into final drive. Tighten case extension bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).
26. Install side cover gasket and seal onto transaxle case. see scheme 26 Install case side cover. see scheme 21 Tighten side cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000).
27. Install cover gasket to 2-1 manual band servo into case. Lubricate gasket with ATF. Install 2-1 manual band servo assembly into case. Ensure servo piston pin engages band. Install accumulator and cover assembly to 2-1 manual band servo into case. Install lube oil pipe into case at lube hole for differential carrier internal gear. Lock lube oil pipe retainer into case. Install cover bolts for 2-1 manual band servo. Install accumulator cover bolts and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000). (Scheme 14)
28. Install NEW oil filter seal, oil filter and pan gasket into case. Install oil pan and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-11645-S00751042052000112200000). Install forward and reverse servo return springs into proper servo bore. Assemble each servo, and then install into case. Install NEW oil seal ring onto each servo cover.
29. Install forward servo cover and bolts. Install reverse servo cover and retaining ring. see scheme 18 Install vehicle speed sensor. Install "O" ring onto turbine shaft. Install torque converter.

CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31