Automatic Transmission - 4L60-E/4L65-E - Overhaul & Testing: Other GMC Savana H2500

GEAR RATIOS

TRANSMISSION GEAR RATIOS

CONVERTER HOUSING

Mount transmission on bench using Holding Fixture (J-8763-02). Remove torque converter. Using 50 mm Torx Plus Bit (J-41510), remove converter housing bolts, and remove converter housing. (Scheme 194)

Removing Torque Converter. Scheme 194

EXTENSION HOUSING

Remove Vehicle Speed Sensor (VSS) retaining bolt. Remove speed sensor assembly and "O" ring. (Scheme 214) Remove extension housing and seal. Remove output shaft sleeve and "O" ring (if equipped). Remove speed sensor rotor from output shaft (if necessary). Install Gear Puller (J-21427-01) and Adapter (J-8433) on rotor. Pull rotor from output shaft. Install Output Shaft Support Fixture (J-29837-A) on output shaft. (Scheme 195)

Scheme 195

VALVE BODY, 1-2 & 3-4 ACCUMULATORS

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

1. Remove transmission oil pan. Remove oil filter and "O" ring. Ensure "O" ring is removed from transmission case. Remove electrical connectors from switches and solenoids, and mark for reassembly reference. (Scheme 196)Remove TCC PWM solenoid retainer clip. Remove solenoid. (Scheme 197)
2. Remove TCC solenoid bolts. (Scheme 198) Remove valve body bolts securing wiring harness. Remove TCC solenoid and allow wiring harness to hang over side of case. (Scheme 199) Remove transmission fluid pressure manual valve position switch. (Scheme 200) Remove detent spring bolt. Remove detent spring. (Scheme 201) Remove remaining valve body bolts. Note length and location of bolts for installation reference. (Scheme 202)
3. Note direction of manual valve link. Remove manual valve link from manual valve at valve body. (Scheme 203) Remove valve body. Note location of check balls on valve body. (Scheme 204)
4. Carefully remove accumulator cover retaining bolts, 1-2 accumulator cover and pin assembly. (Scheme 215) Remove 1-2 accumulator piston, seal and spring. Remove spacer plate beside 1-2 accumulator. Note check ball and filter locations. (Scheme 205) Remove spacer plates. Remove spring, 3-4 accumulator piston and pin. (Scheme 196): Locating Valve Body Solenoids (Scheme 197): Removing TCC PWM Solenoid (Scheme 198): Removing TCC Bolts (Scheme 199): Removing TCC Solenoid & Wire Harness (Scheme 200): Removing Transmission Fluid Pressure Assembly (Scheme 201): Removing Detent Spring Assembly (Scheme 202): Identifying Valve Body Bolt Location

OIL PUMP, INPUT CLUTCH & REVERSE CLUTCH

1. Ensure TCC solenoid assembly and oil filter are removed before oil pump removal. Remove turbine shaft "O" ring. Remove oil pump retaining bolts. Using Oil Pump Remover (J-37789-A) and Adapter (J-39119), pull oil pump assembly free from case. (Scheme 206)
2. Remove oil pump, seal and gasket. Remove reverse input clutch-to-pump thrust washer from pump. Remove band anchor pin from case. (Scheme 213)Lift out input housing, shaft assembly, reverse input clutch housing and drum assembly. (Scheme 207)

Scheme 206

Removing/Installing Input Clutch Assembly. Scheme 207

2-4 BAND, INPUT GEAR SET & REACTION GEAR SET

1. Remove 2-4 band assembly from case. (Scheme 208) Remove input sun gear. (Scheme 216)
2. Remove input carrier-to-output shaft retainer ring. (Scheme 209) Remove input carrier (planetary). Remove input carrier thrust bearing from reaction carrier shaft. (Scheme 210)
3. Remove input internal gear and reaction carrier shaft assembly. (Scheme 211) Remove reaction sun shell and thrust washer. (Scheme 212) Remove reaction sun gear, thrust washer, low-reverse roller clutch race and roller clutch. (Scheme 216)

Removing/Installing 2-4 Band Assembly. Scheme 208

Removing/Installing Input Carrier To Output Shaft Retainer. Scheme 209

Removing/Installing Input Carrier Assembly. Scheme 210

Removing/Installing Input Internal Gear & Reaction Carrier Shaft Assembly. Scheme 211

Removing Thrust Washer & Reaction Sun Shell. Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

LOW-REVERSE CLUTCH

Note. Parking pawl may require removal to access low-reverse clutch.

1. Remove low-reverse support-to-case retaining snap ring. Remove output shaft support fixture. (Scheme 195) Push up on output shaft to loosen low-reverse clutch support. Remove support retainer spring from low-reverse support. Remove low-reverse support assembly and reaction carrier assembly (planetary). (Scheme 216) Remove output shaft.
2. Remove low-reverse clutch plates. Note locations of components. (Scheme 217) Remove internal reaction gear and thrust bearing. Remove internal reaction gear support-to-case thrust bearing. (Scheme 218)
3. Remove parking lock bracket retaining bolts. Remove lock bracket. Using screw extractor, remove shaft plug. Remove parking pawl shaft, parking pawl and return spring if necessary. (Scheme 220)
4. Using Clutch Spring Compressor (J-23327), compress low reverse clutch spring retainer. Remove spring retaining ring and low-reverse spring assembly. Remove low-reverse clutch piston by applying air pressure in case apply passage. (Scheme 219)

Scheme 217

Removing/Installing Internal Reaction Gear & Thrust Bearing. Scheme 218

Scheme 219

INNER MANUAL SHAFT LINKAGE

Remove manual shaft nut. Remove manual shaft and retainer. Remove parking lock actuator assembly and inner detent lever. Remove manual shaft seal from transmission case. (Scheme 220)

Scheme 220

LOW-REVERSE SUPPORT

VALVE BODY

1. Place transmission in a vertical position. Install seals on low-reverse clutch piston. Apply petroleum jelly to seals. Align and install piston with notch in bottom of transmission case (695). Ensure piston is fully seated and parking pawl aligns with opening in piston wall. (Scheme 221) Install the low and reverse clutch spring assembly (694). Using the Clutch Spring Compressor (J23327-1), compress the low and reverse clutch spring assembly (694). Using the Snap Ring Remover and Installer (J36850), install the low and reverse clutch retainer ring (693). (Scheme 222)
2. Coat bearing assembly with petroleum jelly. Install bearing assembly on case hub with outside bearing race toward case hub. Install internal reaction gear and support. Install bearing assembly onto support with outside bearing race toward support. Install oil deflector (if equipped) and reaction carrier assembly in case. (Scheme 216)
3. Place waved plate on work bench. Install 5 composition plates and 4 steel plates alternately, starting with composition plate. Install low-reverse support. Apply light pressure to low-reverse support. Do not flatten waved plate. Measure height of clutch pack from work bench to top of low-reverse support. (Scheme 223)
4. Using height dimension, determine proper selective spacer plate to be used. See «SPACER PLATE SELECTION»(ref-156199-S29089093402003071000000) table. SPACER PLATE SELECTION Measured Clutch Pack Height - In. (mm) (1) Identification Plate Thickness - In. (mm) 1.084-1.105 (27.53-28.07) None.066-.072 (1.67-1.85) 1.105-1.125 (28.07-28.58) "0".046-.052 (1.17-1.31) 1.064-1.084 (27.03-27.53) "1".087-.092 (2.19-2.34) (1) Clutch pack height is measured without spacer plate in position.
5. Place spacer plate between waved plate and first composition plate with identification facing upward. Measure overall height of clutch pack. Overall height should be 1.15-1.18" (29.2-29.9 mm). Install low-reverse clutch pack into transmission case. Ensure clutch plates align with splines of reaction carrier. Ensure steel plates are properly indexed in transmission case. (Scheme 224)
6. Install low-reverse support in case with hub downward. Install inner race by pushing downward while rotating until it is fully engaged. Bottom tangs will be flush with hub when fully installed. Install spring retainer in case between case lug and open notch in support. Install low-reverse snap ring. (Scheme 225)

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

REACTION & INPUT GEAR SETS

1. Install retainer ring on reaction sun gear (if removed). Install sun gear into reaction carrier. Install thrust washer on low-reverse clutch race. Install reaction sun gear shell on reaction sun gear.
2. Install thrust washer on reaction sun gear shell. Ensure thrust washer tangs engage on gear shell. Install input internal gear and reaction carrier shaft in sun gear shell. Carrier shaft splines must engage with reaction carrier. (Scheme 216)
3. Install thrust washer on reaction carrier shaft. Outer race must face toward reaction carrier shaft. Install output shaft in transmission. Ensure output shaft engages with all parts.
4. Install Output Shaft Support (J-29837-A). (Scheme 195) Adjust support so output shaft is positioned upward as far as possible. Install input carrier (planetary) assembly with hub end down on output shaft. Install NEW retainer ring on output shaft. Remove output shaft support. Install input sun gear, indexing gear end with input carrier pinions.

TRANSMISSION END PLAY CHECK

1. Install Pump Remover/End Play Fixture (J-24773-A) and End Play Adapter (J-25022-A) on end of turbine shaft. (Scheme 226) Clamp dial indicator on long bolt with indicator tip on end play fixture. Zero dial indicator.
2. Pull up on end play fixture. Measure transmission end play. Transmission end play should be.005-.036" (.13-.91 mm). If transmission end play is not within specification, selective thrust washer must be changed between oil pump and input housing. (Scheme 216) Install appropriate thrust washer, and recheck end play. See «OIL PUMP THRUST WASHER SPECIFICATIONS»(ref-156199-S16656892732003071000000) table.

OIL PUMP THRUST WASHER SPECIFICATIONS

Scheme 226

1. Install 3-4 accumulator piston pin in case. Install 3-4 piston seal on piston. Install 3-4 accumulator piston on pin. Legs of piston must face valve body.
2. Install 3-4 accumulator spring. Install oil screens in proper locations. (Scheme 227) (Scheme 205)for check ball and filter installation locations. Install alignment pins in transmission case to aid spacer plate and valve body installation. Install spacer plate gasket and spacer plate. Install spacer plate support.
3. Install 1-2 accumulator spring, oil seal ring and 1-2 accumulator piston. Install accumulator cover and bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000).
4. Coat check balls with petroleum jelly. Install check balls in proper locations in valve body. (Scheme 204)and (Scheme 205). Install manual valve link. Ensure manual valve link is properly seated in manual valve. (Scheme 203) Improper positioning may prevent vehicle operation in "D" range. NOTE: Improper positioning of throttle valve link will result in erratic shift points or high oil pressure.
5. Install valve body and retaining bolts. Ensure correct length and location of bolts. (Scheme 202) Install detent spring. Install detent spring bolt. Install transmission fluid pressure manual valve position switch. Install TCC solenoid. Install valve body bolts that secure wiring harness. Tighten all valve body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-156199-S19960075452003071000000).
6. Install TCC PWM solenoid. Install retainer clip. Install electrical connectors to switches and solenoids. (Scheme 196) Install oil filter and "O" ring. Install transmission oil pan.

Scheme 227

1. Install speed sensor rotor retaining clip on output shaft. Install "O" ring in output shaft sleeve. Install output shaft sleeve on output shaft. DO NOT position output shaft sleeve past machined surface of output shaft. Install seal ring on extension housing.
2. Position extension housing on transmission case. Install retaining bolts. Install oil seal in extension housing. Install speed sensor assembly. Install retainer and bolt. Tighten bolt to specification. Install outside electrical connector. Install PNP switch and manual shift lever. See PARK/NEUTRAL POSITION SWITCH under REMOVAL & INSTALLATION.

Scheme 228

Scheme 229