Automatic Transmission Overhaul - 4l80-e GMC Savana I

APPLICATION

4L80-E TRANSMISSION APPLICATIONS

IDENTIFICATION

Transmission is identified by metal identification plate attached to rear face of transmission case. (Scheme 72)

Scheme 72

GEAR RATIOS

TRANSMISSION GEAR RATIOS

DESCRIPTION & OPERATION

The Hydra-Matic 4L80-E transmission is a fully automatic 4-speed unit consisting primarily of a hydraulic torque converter and torque converter clutch. Transmission uses a gear-type oil pump to supply all hydraulic pressure needed for operation. Other internal components include 5 multiple disc clutches, 2 roller clutches, a sprag clutch, 2 bands, 2 speed sensors and 3 compound planetary gear sets. (Scheme 73)

The Hydra-Matic 4L80-E also uses 2 electronic shift solenoids. Shift solenoids are controlled by the Powertrain Control Module (PCM), Transmission Control Module (TCM), or Vehicle Control Module (VCM), depending on vehicle model and engine application.

Scheme 73

LUBRICATION

See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING for additional information.

RECOMMENDED FLUID

Manufacturer recommends Dexron III ATF.

FLUID CAPACITIES

TRANSMISSION FLUID CAPACITIES (1)

ON-VEHICLE SERVICE

The following components can be serviced without transmission removal

1. Accumulator Assemblies
2. Case Extension
3. Filler Pipe
4. Low/Reverse Servo
5. Manual 2-1 Servo
6. Park/Neutral Position Switch
7. Shift Solenoids
8. Speedometer Driven Gear & Seal
9. Speed Sensors
10. Valve Body

Note. For removal and installation procedures of listed components, see REMOVAL & INSTALLATION .

OIL COOLER FLUSHING

1. If available, fill Oil Cooler and Line Flushing Tool (J-35944-A) with flushing solution. Connect flushing tool to transmission end of oil cooler line that feeds bottom fitting of oil cooler. Connect discharge hose to top oil cooler line. Follow manufacturer's instructions to flush oil cooler and cooler lines.
2. If flushing tool is not available, flush cooler and cooler lines with a mixture of clean solvent and water. Flush cooler in both directions until all old fluid and debris are removed. If necessary, replace plugged or damaged cooler and/or lines.

TROUBLE SHOOTING

Note. For electrical trouble shooting, see appropriate HYDRA-MATIC 4L80-E ELECTRONIC CONTROLS article. For elements in use for specified gear selector positions, see CLUTCH & BAND APPLICATION table.

PRELIMINARY INSPECTION

1. Check transmission fluid level and condition. Check PCM/TCM/VCM memory for any stored Diagnostic Trouble Codes (DTC) and repair as necessary. See appropriate HYDRA-MATIC 4L80-E ELECTRONIC CONTROLS article. If no DTCs are stored, go to next step.
2. Perform road test. See «ROAD TEST»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e__road-test) under PERFORMANCE TESTS. During road test, record shift points. If shift point timing or shifting is incorrect, see appropriate HYDRA-MATIC 4L80-E ELECTRONIC CONTROLS article.
3. If shift(s) is too harsh or too soft, see «HYDRAULIC PRESSURE TESTS»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e__hydraulic-pressure-tests) under PERFORMANCE TESTS. For specific complaints, see condition(s) listed under «SYMPTOM DIAGNOSIS»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e) .

High Line Pressure

Stuck pressure regulator or reverse boost valves. Broken retainer pin. Blocked orifice plug. Faulty pressure control solenoid valve or connector. Loose connection at PCM/TCM/VCM.

Forward Motion In Neutral

Manual valve mispositioned or stuck. Forward clutch piston, springs or plates jammed. Holes in forward clutch housing or hub are plugged.

Inadequate Lubrication At Low Line Or Heavy Loads

Stuck converter limit valve. Broken retainer pin.

Inadequate Lubrication

Stuck pressure regulator valve. Cross-channel leakage in pump body. Damaged pump body gasket. Leaking oil transfer hole cup plug.

Engine Stalls In Neutral

TCC stuck on or dragging.

Loss Of Power

Transmission fluid level low or not starting in 1st gear. TCC stuck on or dragging. Debris in torque converter. Broken stator shaft. Worn bearings. Worn turbine, main or output shaft bushings.

No Torque In Reverse Or 3rd

Broken forward clutch hub. Snap ring not seated. Broken forward clutch housing. Broken direct clutch piston.

Transmission Overheats

TCC circuit blockage. Broken TCC valve spring. Cross-channel leakage in pump cover. Stuck pressure regulator valve. Blocked oil cooler or lines. Damaged pump gasket. Broken retainer pin. Damaged turbine shaft "O" ring or seals. Worn or damaged stator shaft bushing. Leaking oil transfer hole cup plug. Low fluid level. Restricted radiator air flow.

Transmission Overheats At WOT

Converter limit valve by-pass orifice cup plug blocked (converter limit valve stuck closed).

Low Line Pressure

Cross-channel air leak at pump body-to-cover or pump body-to-case gasket. Stuck pressure regulator or reverse boost valve. Worn pump valve bores. Broken valve springs or retainer pin. Valve body cross-channel leaks. Damaged or missing valve body gasket or spacer plate. Pressure control solenoid valve: stuck, missing screen, wires shorted to ground, or broken clip. Faulty PCM/TCM/VCM.

Engine Starts In Gear

Manual valve mispositioned or not engaged with detent lever. Park/neutral position switch inoperative.

Shift Lever Indicates Wrong Gear

Manual valve not engaged with detent lever. Misaligned or broken detent pin. Manual shaft flats are not parallel. Misadjusted indicator linkage.

No Gear Selection

Loose or missing detent lever nut. Stuck manual valve. Spacer plate holes are blocked. Valve body or case channels are blocked.

No Drive

Faulty torque converter. Faulty oil pump. Damaged case extension seal. Leaking or missing orifice plate. Damaged oil pump gasket. Leaking or missing oil transfer hole cup plug. Leaking oil pump seals. Overrunning clutch housing broken. Roller clutches worn, broken or locked. Broken carrier. Worn or damaged pinion assemblies. Broken overrun clutch housing bearing. Broken turbine shaft splines. Worn or damaged forward clutch components. Worn or broken rear gear set components. Faulty turbine shaft ball seal. Broken main shaft splines. Fluid pressure too low.

No Park

Problem with detent components. Broken actuator rod. Damaged park pawl gear and components. Manual shaft flats are not parallel.

Remains In Park

Stretched actuator rod assembly.

Difficult To Shift From Park

Weak or broken pawl return spring. Vehicle parked on hill.

Does Not Remain In Park

Weak or broken detent spring.

No Reverse Or Slips In Reverse

Broken or mispositioned low/reverse band anchor pin. Center support leaking or broken. Center support bolt loose, broken or feed hole is blocked. Low/reverse band broken or not anchored. Low/reverse band apply pin too short or binding. Incorrect boost valve and sleeve combination installed. Low/reverse servo problem. Worn or damaged direct clutch components.

No 1st Gear ("D1")

Faulty low roller assembly. Broken center support or splines. Damaged case near center support. Center support retaining rings not seated. Broken overrun clutch housing. Broken or mispositioned low/reverse band anchor pin. Misaligned detent lever.

No 2nd Gear ("D1")

Missing or mispositioned intermediate clutch feed cup plug. Damaged, worn or missing intermediate clutch components. Center support oil hole blocked. Damaged center support components. Worn or damaged intermediate sprag. Broken direct clutch housing. Improper transmission fluid.

No Overrun Braking ("D1")

Faulty overrun clutch plates. Damaged or worn selective thrust washer. Output shaft or splines broken. Cut or nicked seals. Leaking check ball. Worn sun gear. Damaged overrun piston or housing. Jammed spring assembly. Check for DTCs. Transmission fluid pressure manual valve position switch assembly: pinched wires, loose connector, loose bolt or no signal to control module.

No Engine Braking ("D1")

Problem with low/reverse band, apply pin or low/reverse servo assembly. Fluid pressure too low. Output shaft or splines broken. Main shaft or splines broken. Turbine shaft rear bushing worn or damaged. Selective thrust washer worn or damaged.

No 1st Gear ("D2")

Faulty low roller assembly. Broken center support or splines. Damaged case near center support. Center support retaining rings not seated. Manual 2-1 band stuck on.

No 2nd Gear ("D2")

Missing or mispositioned intermediate clutch feed cup plug. Damaged, worn or missing intermediate clutch components. Center support oil hole blocked. Damaged center support components. Worn or damaged intermediate sprag. Broken direct clutch housing. Improper transmission fluid. Problem with manual 2-1 band anchor pin. Intermediate clutch feed cup plug missing or not seated.

No Overrun Braking ("D2")

Faulty overrun clutch plates. Damaged or worn selective thrust washer. Output shaft or splines broken. Cut or nicked seals. Leaking check ball. Worn sun gear. Damaged overrun piston or housing. Jammed spring assembly.

No Engine Braking ("D2")

Worn or damaged turbine shaft rear bushing. Worn or damaged selective thrust washer. Spalled or broken rear gear set. Broken reaction drum and carrier. Main, output or sun gear shafts/splines broken.

No 2nd Gear Engine Braking ("D2")

Fluid pressure too low. Worn direct clutch housing (inner splines or outer band surface). Manual 2-1 band components worn, damaged or binding. Manual 2-1 band servo components damaged, worn or binding. Valve body spacer plate or gasket damaged. Loose valve body bolts. Damaged case.

No 1st Gear ("D3")

Faulty low roller assembly. Broken center support or splines. Damaged case near center support. Center support retaining rings not seated. Manual 2-1 band stuck on.

No 2nd Gear ("D3")

Missing or mispositioned intermediate clutch feed cup plug. Damaged, worn or missing intermediate clutch components. Center support oil hole blocked. Damaged center support components. Worn or damaged intermediate sprag. Broken direct clutch housing. Improper transmission fluid.

No 3rd Gear ("D3")

Direct clutch components worn, damaged or leaking. Center support components broken or leaking. Center support bolt loose or blocked hole. 2-3 solenoid: stuck off, pinched wire, faulty "O" ring or no voltage. No signal to 2-3 solenoid from control module. Stuck 2-3 shift valve. Faulty quad driver module. Manual 2-1 band stuck on.

No Overrun Braking ("D3")

Faulty overrun clutch plates. Damaged or worn selective thrust washer. Output shaft or splines broken. Cut or nicked seals. Leaking check ball. Worn sun gear. Damaged overrun piston or housing. Jammed spring assembly.

No Engine Braking ("D3")

Main shaft or splines broken. Turbine shaft rear bushing damaged or worn.

No 1st Gear ("D4")

Faulty low roller assembly. Broken center support or splines. Damaged case near center support. Center support retaining rings not seated.

1st Gear Only ("D4")

Sun gear shaft or splines broken. Input or output speed sensors read zero.

1st & 2nd Gear Only ("D4")

2-3 solenoid: stuck off, loose connector, no voltage to solenoid, faulty solenoid "O" ring or no signal to solenoid from control module. 2-3 shift valve stuck. Faulty quad driver module. Check for DTCs.

2nd Gear Only ("D4")

Check for DTCs.

2nd & 3rd Gear Only ("D4")

1-2 solenoid: stuck off, loose connector, no voltage to solenoid, faulty solenoid "O" ring or no signal to solenoid from control module. 1-2 shift valve stuck. Faulty quad driver module. Check for DTCs.

1st & 4th Gear Only ("D4")

1-2 solenoid stuck on or wire shorted to ground. 1-2 shift valve stuck. Faulty quad driver module. Check for DTCs.

3rd & 4th Gear Only ("D4")

2-3 solenoid stuck on or wire shorted to ground. 2-3 shift valve stuck. Faulty quad driver module. Check for DTCs.

No 2nd Gear ("D4")

Missing or mispositioned intermediate clutch feed cup plug. Damaged, worn or missing intermediate clutch components. Center support oil hole blocked. Damaged center support components. Worn or damaged intermediate sprag. Broken direct clutch housing. Improper transmission fluid.

No 3rd Gear ("D4")

Direct clutch components worn, damaged or leaking. Center support components broken or leaking. Center support bolt loose or blocked hole. 2-3 solenoid: stuck off, pinched wire, faulty "O" ring or no voltage. No signal to 2-3 solenoid from control module. Stuck 2-3 shift valve. Faulty quad driver module.

No 4th Gear ("D4")

Fourth clutch components worn or damaged. Overrun clutch components worn or damaged. 1-2 solenoid: stuck off, pinched wire, faulty solenoid "O" ring or no voltage or signal to solenoid. 3-4 shift valve stuck. Faulty quad driver module. Check for DTCs.

No Torque Converter Clutch (TCC) Apply

TCC shift solenoid valve: stuck off, faulty "O" ring, no voltage or signal to solenoid, poor connection. Faulty quad driver module. Brake switch: corroded contacts, poor connection, pinched wire, misadjusted, no supply voltage. TCC valve stuck off. Broken retainer pin. Ballooning torque converter. Plugged turbine shaft oil holes. Faulty turbine shaft seals. Worn pump body bushing. Damaged turbine shaft front oil seal. Leaking oil transfer hole cup plug. Stuck regulated apply valve. Blocked TCC valve release exhaust orifice cup plug. Check for DTCs.

Soft Torque Converter Clutch (TCC) Apply

Faulty turbine shaft seals. Worn pump body bushing. Defective turbine shaft front oil seal. Leaking oil transfer hole cup plug. Faulty TCC solenoid. Low oil pressure.

Torque Converter Clutch (TCC) Slipping

Blocked TCC valve release exhaust orifice cup plug. Cut turbine shaft seal.

Torque Converter Clutch (TCC) Stuck On

Damaged oil pump gasket. TCC shift solenoid valve stuck on or wire shorted to ground. TCC apply valve stuck. Faulty quad driver module. Check for DTCs.

Incorrect Torque Converter Clutch (TCC) Apply Or Release

Output shaft speed sensor: poor connection, pinched wire, broken coil wire, incorrect air gap, or faulty signal. TP sensor: poor connection, pinched wire, or incorrect resistance. Faulty control module. Transmission fluid pressure manual valve position switch: poor connection, no signal to control module, or pinched wire. Fluid temperature sensor assembly: poor connection, no signal to control module, incorrect resistance, or pinched wire. No engine coolant signal to control module. Brake switch: poor connection, pinched wire, no voltage supply, or misadjusted. Intermittent or loss of ignition module signal. Check for DTCs. Digital Ratio Adapter (DRAC) malfunctioning or incorrect (2WD only).

Torque Converter Ballooning

Converter limit valve stuck open. Converter limit valve feedback orifice cup pluck blocked at high speeds. Converter stator locked-up.

No Torque Multiplication

Stator shaft broken or detached from pump cover.

Fluid Foaming

Transmission overfilled or contaminated with antifreeze. Engine overheating. Filter cracked or not seated. Damaged filter seal. Vehicle overloaded.

Noise

Torque converter: loose lug bolts, out of balance, or internal failure. Transmission/engine misaligned. Worn case extension output shaft support bushing.

Engine Stalls

Seized or Jammed fourth or overrun clutch components.

Vibration

Torque converter out of balance or internal failure. Transmission/engine misaligned. Worn case extension output shaft support bushing. Worn stator shaft bushing surface on turbine shaft. Worn bearings. Worn main or output shaft bushings.

Oil Out Vent Tube

Cross-channel leak allowing pressure to leak into vent area of pump cover. Pump vent ports filled with foaming fluid. Transmission overfilled or overheating.

No Torque In 2nd Gear

Intermediate sprag worn, excessive eccentricity, or sprag is rolled over or damaged.

2nd Gear Starts

Intermediate clutch plates seized. Direct clutch lube feed blocked. Center support springs or piston jammed. 1-2 shift solenoid valve: stuck off, faulty "O" ring, no voltage to solenoid, or poor connection. No signal to solenoid from control module. Faulty quad driver module. 1-2 shift valve stuck. Check for DTCs.

3rd Gear Starts

Holes plugged in forward clutch driving hub. Forward clutch plates seized. Direct clutch lube feed hole blocked. Direct clutch piston or spring assembly jammed.

4th Gear Starts

2-3 shift solenoid valve stuck on or wire shorted to ground. Check for DTCs.

Erratic Shift Quality

Damaged oil pump gasket. Leaking oil transfer hole cup plug. Damaged overrunning clutch housing oil seal rings.

Transmission Slips

Incorrect fluid level.

Failed Case Extension Bearing/Seal

Orifice plate hole is blocked or missing.

Inaccurate Shift Points

Output shaft speed sensor: pinched or broken wire, loose connector, incorrect air gap, inadequate signal, damaged coil or damaged rotor teeth. TP sensor: pinched or broken wire, incorrect resistance, loose connector, or faulty control module. Fluid pressure manual valve position switch assembly: loose connector, loose bolts, pinched wire, or no signal to control module. Axle ratio incorrect. Tire size incorrect. Check for DTCs. Digital Ratio Adapter (DRAC) malfunctioning or incorrect (2WD only).

Harsh Shifts (All)

Incorrect line pressure. Pressure control solenoid valve faulty or loose connector. Loose control module connector. Accumulator piston leaking or stuck. Incorrect accumulator spring. Missing check balls. Incorrect PROM calibration. Check for DTCs.

Harsh Shift (Drive-Reverse)

Direct lube exhaust blocked. Forward clutch spring not acting. Direct clutch backing plate retainer ring not seated. Check ball plugged.

Harsh Shift (3-4)

4th clutch not compressing evenly. Air bleed plugged.

Harsh Shift (4-3)

4th clutch retainer ring not seated. 4th clutch spring assembly not acting. 4th clutch housing bolt oil feed hole plugged. Plugged 4th clutch cup plug. Blocked direct lube exhaust.

Harsh Shift (D4-D3, D2, Or D1)

Overrun clutch spring assembly not functioning. Check ball plugged. Overrun clutch backing plate snap ring not seated.

Soft Shifts (All)

Line pressure too low. Pressure control solenoid valve: stuck on, broken clip, or wire shorted to ground. Faulty control module. Accumulator piston leaking or stuck. Incorrect accumulator spring. Incorrect PROM calibration. Check for DTCs.

Soft Shift (Reverse)

Plugged direct clutch oil feed. Blocked direct lube exhaust.

Soft Shift (Reverse-Drive)

Direct clutch spring not acting. Direct clutch backing plate retainer ring missing or not engaged. Check ball plugged.

Soft Shift (2-1)

Center support springs not acting. Intermediate clutch spring retainer ring not seated. Center support air bleed blocked.

Soft Shift (2-3)

Direct clutch oil feed plugged. Direct lube exhaust blocked.

Soft Shift (3-2)

Direct spring assembly not acting. Forward clutch spring retainer ring missing or not engaged. Check ball plugged.

Soft Shift (D3-D2)

Missing check balls. Incorrect sized orifices.

Delayed 1-2 Shift

Output speed sensor: pinched or broken wire, loose connector, incorrect air gap, inadequate signal, or coil damage. Input speed sensor: pinched or damaged wire, coil damage, or inadequate signal. Fluid pressure manual valve position switch assembly: loose connector, pinched wire, no signal to control module, or loose bolts. Incorrect PROM calibration. Check for DTCs. Digital Ratio Adapter (DRAC) malfunctioning or loose connector (2WD only).

No D2-D1 Shift

Low/reverse band broken, worn or not anchored. Incomplete detent lever travel.

No D3-D2 Shift

Manual 2-1 band broken, worn or not anchored.

Oil Pan Leak

Damaged oil pan, gasket or case. Oil pan flange not flat. Improperly torqued oil pan bolts.

Fill Tube Fluid Leak

Fill tube seal missing or cut. Case porosity. Fill tube damaged or not seated. Fill tube bracket out of position.

Electrical Connector Fluid Leak

Connector damaged or not seated. "O" ring missing or cut. Case porosity or cracked.

Cooler Line Fluid Leaks

Stripped threads. Damaged flare. Improper torque. Debris in threads. Case porosity.

Case Extension Fluid Leaks

Case or case extension porosity or crack. Seal missing or cut. Missing or improperly torqued bolts.

Manual Shaft Fluid Leak

Seal missing or cut. Misadjusted linkage.

Pump Body Seal Fluid Leak

Seal cut or worn. Missing seal garter spring. Damaged torque converter hub. Improper pump bolt torque.

Vehicle Sped Sensor (VSS) Fluid Leak

Seal cut or missing. VSS damaged, not seated, or damaged bracket. Bolts missing or improperly torqued. Case porosity or cracked.

Output Shaft Seal Fluid Leak

Seal cut or nicked. Case porosity or cracked.

Line Pressure Plug Fluid Leak

Stripped plug threads or improperly torqued. Case porosity, cracked or damaged threads.

CLUTCH & BAND APPLICATION

CLUTCH & BAND APPLICATION

PERFORMANCE TESTS

Note. Shift speed charts reference percentage of throttle angle instead of minimum or wide open throttle position. This measurement is more accurate. A scan tool should be used to monitor throttle angle. Before road testing vehicle, engine and transmission must be at normal operating temperature. Torque converter clutch will not engage if engine coolant has not reached normal operating temperature.

ROAD TEST

Perform road test with scan tool connected to vehicle. PCM/TCM calculates upshift points based primarily on throttle position and vehicle speed. Ensure scan tool parameters for electronic transmission components are within tolerance. See appropriate HYDRA-MATIC 4L80-E ELECTRONIC CONTROLS article.

When PCM/TCM determines a shift should occur, the ground circuit is closed or opened to shift solenoids. Solenoids move shift valves to perform shift. A scan tool should be used during road test to monitor throttle position. Some scan tools are capable of recording shift point information. Check scan tool instruction manual to determine if this test is available.

Gear Selector In "D" Position

Note. Ensure TCC engages in 3rd or overdrive gears during the following steps. Transmission is equipped with a Pulse Width Modulated (PWM) solenoid, which can make TCC engagement difficult to detect. If necessary, a scan tool may be used to indicate TCC and shift solenoid operation.

1. With gear selector in "D" position, steadily increase throttle pressure to accelerate vehicle. Note shift speed engagement points in 2nd, 3rd and overdrive gears. Use shift speed charts as a reference for correct shift speeds. (Scheme 74)- (Scheme 78). Also note when Torque Converter Clutch (TCC) engages while in 3rd or overdrive gears.
2. With vehicle speed at 40-50 MPH, quickly depress accelerator to half open position (part throttle detent downshift). TCC should release, 1-2 shift solenoid turns off, and transmission should immediately downshift into 3rd gear.
3. With vehicle speed at 40-50 MPH, quickly depress accelerator to wide open position (full throttle detent downshift). TCC should release, 1-2 and 2-3 shift solenoids turn off, and transmission should immediately downshift into 2nd gear.
4. With vehicle speed at 40-55 MPH, release accelerator pedal while moving gear selector into "3" position. TCC should release, transmission should downshift into 3rd gear, and engine braking should slow vehicle.
5. Move gear selector into "D" position, and accelerate vehicle to 40-45 MPH. Release accelerator pedal while moving gear selector into "2" position. TCC should release, transmission should downshift into 2nd gear immediately, and engine braking should slow vehicle.
6. Move gear selector into "D" position, and accelerate vehicle to 30 MPH. Release accelerator pedal while moving gear selector into "1" position. TCC should release, transmission should downshift into 1st gear, and engine braking should slow vehicle.
7. With gear selector in "D" position, accelerate vehicle to 4th gear with TCC applied. Release accelerator pedal, and lightly apply brakes. TCC should release. Note vehicle speeds at which vehicle downshifts. (Scheme 74)- (Scheme 78).

Gear Selector In "3" Position

With vehicle stopped, move gear selector into "3" position. Steadily increase throttle pressure to accelerate vehicle. Note vehicle speeds at which vehicle shifts into 2nd and 3rd gears. (Scheme 74)- (Scheme 78). Ensure TCC engages while in 3rd gear.

Gear Selector In "2" Position

With vehicle stopped, move gear selector into "2" position. Accelerate vehicle, and note vehicle speed at which vehicle shifts from 1st to 2nd gear. Accelerate vehicle to 35 MPH. Transmission should NOT shift into 3rd gear, and TCC should NOT engage.

Gear Selector In "1" Position

With vehicle stopped, move gear selector into "1" position. Accelerate vehicle to 20 MPH. Transmission should NOT upshift, and TCC should NOT engage.

Gear Selector In "R" Position

With vehicle stopped, move gear selector into "R" position. Verify 1-2 shift solenoid is on and 2-3 shift solenoid is off.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

HYDRAULIC PRESSURE TESTS

1. Before performing hydraulic pressure tests, check fluid level and condition. Check manual control linkages for correct adjustment, and ensure engine is properly tuned.
2. Connect scan tool to Data Link Connector (DLC). Apply parking brake and start engine. Check for Diagnostic Trouble Codes (DTC). If DTCs are present, diagnose as necessary. See appropriate HYDRA-MATIC 4L80-E ELECTRONIC CONTROLS article. Turn engine off. Connect oil pressure gauge to line pressure test port. (Scheme 79)
3. Start engine and warm to normal operating temperature. With transmission in Reverse, line pressure should be 67-324 psi (462-2234 kPa). With transmission in Park, Neutral or Drive, line pressure should be 35-171 psi (241-1179 kPa).
4. Shift transmission into Park. Access Pressure Control Solenoid (PCS) test on scan tool. Increase PCS current in 0.1 amp increments and read corresponding line pressure on oil pressure gauge. Allow pressure to stabilize for 5 seconds after each current change. Compare readings to specifications. See «LINE PRESSURE SPECIFICATIONS»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e) table. If pressure readings are not as specified, and no DTCs are present, an internal malfunction exists. See «TROUBLE SHOOTING»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e__trouble-shooting).

Note. Scan tool is only able to control PCS in Park and Neutral with vehicle stopped. This protects clutches from extremely high or low pressures in Reverse and Drive.

LINE PRESSURE SPECIFICATIONS

Scheme 79

TORQUE CONVERTER

Note. For additional torque converter clutch diagnostic information, see appropriate HYDRA-MATIC 4L80-E ELECTRONIC CONTROLS article.

Stall Speed Test

1. Torque converter whine is usually noticed when vehicle is stopped and transmission 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. Stall speed test is used to ensure whine is coming from torque converter.
2. Start engine, and allow it to reach normal operating temperature. Apply parking and service brakes. Put transmission in Drive. Depress accelerator to increase engine speed to about 1200 RPM for less than 6 seconds. Torque converter noise will increase under this load.

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

Stator Check (On-Vehicle)

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 stand still. Vehicle may act normal at speeds greater than 30-35 MPH.
2. If poor acceleration is noted, ensure exhaust system is not restricted, engine timing is correct and transmission is in 1st gear when starting from a stop. If stator is locked up at all times, performance from a stand still appears normal. Engine RPM and acceleration is limited at high speeds. Engine may overheat from this condition.

Inspection

Torque converter must be replaced under the following conditions

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.

End Play Check

Mount Torque Converter End Play Fixture (J-39195) and Dial Gauge (J-8001) with Magnetic Indicator Base (J-26900-13) on torque converter to check end play. Push down on fixture handle to bottom stator. Zero dial gauge. Pull up on fixture handle and check reading. End play should be 0-.024" (0-0.61 mm). (Scheme 80)

Scheme 80

Stator Check (Bench Test)

A visual inspection of torque converter may reveal converter is Blue from overheating. Stator roller clutch can be checked by inserting a finger into splined inner race of roller clutch and trying to turn race in both directions. Inner race should turn freely clockwise, but should not turn or should be difficult to turn counterclockwise.

REMOVAL & INSTALLATION

Note. Removal and installation procedures of components not listed here are covered throughout transmission disassembly and reassembly procedures.

Remove dipstick. Remove filler tube-to-transmission nut. Remove top half of filler tube. Remove lower halve of filler tube and oil seal. To install, reverse removal procedure using NEW oil seal. Tighten filler tube-to-transmission nut to 24 ft. lbs. (32 N.m).

Removal

1. Apply parking brake. Place transmission in Neutral. Raise and support vehicle. Remove transmission control lever-to-manual shaft nut. Remove transmission control lever. Disconnect Park/Neutral Position (PNP) switch harness connector on vehicle harness.
2. Remove PNP switch-to-transmission bolts. Remove PNP switch from manual shaft.

Installation

1. Place PNP switch on manual shaft and loosely install mounting bolts. Position Alignment Tool (J-41364-A) onto PNP switch. Ensure slots on switch are aligned with tabs on alignment tool. (Scheme 81)
2. Rotate alignment tool until locator pin on alignment tool is lined up with slot on top of switch. Tighten PNP switch-to-transmission bolts to 18 ft. lbs. (24 N.m). Remove alignment tool.
3. Reconnect wiring harness. Install transmission control lever and tighten nut to 18 ft. lbs. (24 N.m). Lower vehicle. Ensure engine starts in Park and Neutral only.

Scheme 81

1. Raise and support vehicle. Remove oil pan and filter. Remove nut, pin, detent lever and actuator assembly. Remove bolts and parking lock bracket. Remove parking pawl return spring.
2. Using a modified screw extractor, remove parking pawl shaft plug. Remove shaft retainer, shaft and pawl. Remove oil seal and manual shaft.
3. To install, reverse removal procedure using NEW manual shaft oil seal. Install parking pawl shaft plug with Loctite®. Tighten parking lock bracket bolts to 18 ft. lbs. (24 N.m). Refill transmission. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

1. Raise and support vehicle. Remove oil pan and filter. Remove reverse boost valve bushing retainer ring. (Scheme 123) Remove reverse boost valve and pressure regulator valve components from pump bore.
2. Pre-assemble clean valve components with Transjel® (J-36850). To install, reverse removal procedure. Ensure retainer ring is fully seated into pump bore groove. Refill transmission. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

1. Raise and support vehicle. Remove oil pan and filter. Remove valve bore plug retainer ring. (Scheme 123) Remove TCC valve components from pump bore.
2. To install, reverse removal procedure. Ensure retainer ring is fully seated into pump bore groove. Refill transmission. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

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

1. Remove oil pan, gasket and oil filter. Remove wiring harness. (Scheme 83)and (Scheme 143). Remove accumulator assemblies. (Scheme 84)and (Scheme 128). Remove TFP position switch (also referred to as pressure switch assembly). (Scheme 84)
2. Remove valve body bolts in a spiral pattern in numerical order. (Scheme 144) Remove valve body assembly. Remove spacer plates and gasket. (Scheme 84) Remove check balls and PWM solenoid screen from case. (Scheme 85)

1. Install check balls in case. Check ball No. 2 is only used on some models. (Scheme 85) Assemble and install accumulator assembly. (Scheme 128) Tighten accumulator assembly bolts in sequence. (Scheme 142)
2. Install valve body assembly and TFP position switch. Tighten TFP position switch bolts to 97 INCH lbs. (11 N.m) in alphabetical sequence. (Scheme 143) Tighten valve body bolts in a spiral pattern in numerical order. (Scheme 144) Install lube pipe and wiring harness. (Scheme 143) Install oil pan and oil filter. (Scheme 83)

Raise and support vehicle. Disconnect VSS harness connector. Remove VSS-to-transmission bolt. Remove VSS and "O" ring from transmission. To install, reverse removal procedure using NEW "O" ring coated with transmission fluid. Tighten VSS-to-transmission bolt to 97 INCH lbs. (11 N.m). Check transmission fluid level. See appropriate AUTOMATIC TRANSMISSION SERVICING article in TRANSMISSION SERVICING.

CASE EXTENSION & SPEED SENSORS

Thoroughly clean transmission exterior. Drain fluid and remove torque converter. Place transmission in holding fixture. Using slide hammer, remove slip yoke seal. Remove case extension bolts, case extension and seal. Remove case extension bearing assembly (some models). Remove input speed sensor and output speed sensor (output speed sensor plug on 4WD models). (Scheme 82)

Scheme 82

LOWER TRANSMISSION ASSEMBLY

1. Remove oil pan, gasket and oil filter. Remove wiring harness. (Scheme 83)and (Scheme 143). Remove accumulator assemblies. (Scheme 84)and (Scheme 128). Remove TFP position switch (also referred to as pressure switch assembly). (Scheme 84)
2. Remove valve body bolts in a spiral pattern in numerical order. (Scheme 144) Remove valve body assembly. Remove spacer plates and gasket. (Scheme 84) Remove check balls and PWM solenoid screen from case. (Scheme 85) Remove parking pawl and manual linkage. (Scheme 86)

Scheme 83

Scheme 84

Scheme 85

Scheme 86

SERVO ASSEMBLIES

Remove servo covers and assemblies. (Scheme 84), (Scheme 126) and (Scheme 127).

Low/Reverse Band Apply Pin Selection

1. Install Band Apply Selector Pin (J-21370-10) into servo bore. (Scheme 87) Mount Band Apply Pin Selector Gauge (J-38737) and selector pin on transmission. (Scheme 88) Apply 25 ft. lbs. (34 N.m) of torque to hex nut on gauge.
2. Note which step on selector pin lines up with top edge of apply pin gauge. Use this information to determine pin length. (Scheme 87)and (Scheme 89). Record length for reassembly. Pins are available in various lengths. (Scheme 89)

Scheme 87

Scheme 88

Scheme 89

END PLAY CHECKS

1. Using dial indicator, check front and rear unit end play. (Scheme 90)and (Scheme 91). Press down on turbine shaft, and then pull up on turbine shaft to eliminate any clearance between overdrive carrier and snap ring. Pull up on turbine shaft while holding output carrier upward with screwdriver to measure front unit end play. Front unit end play should be.004-.022" (.10-.56 mm).
2. Push in on output shaft to take up any slack. Move output shaft inward and outward to measure rear unit end play. Rear unit end play should be.005-.025" (.13-.64 mm). Record measurements for reassembly reference.

Scheme 90

Scheme 91

OIL PUMP ASSEMBLY

Using appropriate puller, remove torque converter oil seal. Remove oil pump assembly-to-transmission case bolts. Using Removal Tool (J-37789-A), remove oil pump assembly. Remove gasket and thrust washer. (Scheme 141)

OVERDRIVE ASSEMBLY & 4TH CLUTCH

Remove turbine shaft and overdrive carrier assembly. (Scheme 114) Using appropriate Torx wrench, remove 4th clutch housing bolt and discard. (Scheme 92) Remove 4th clutch assembly.

Scheme 92

FORWARD & DIRECT CLUTCH

Using Clutch Remover/Installer (J-38358-A), remove forward clutch assembly. (Scheme 136) Using Clutch Remover/Installer (J-38733), remove direct clutch assembly. (Scheme 135)

MANUAL 2-1 BAND & INTERMEDIATE CLUTCH

Note. Manual 2-1 band may also be referred to as front band.

Remove manual 2-1 band. Remove snap ring, backing plate and intermediate clutch plates. Remove intermediate clutch wave plate. (Scheme 134)

CENTER SUPPORT, REAR GEAR UNIT & LOW/REVERSE BAND

Note. Low/reverse band may also be referred to as rear band.

1. Remove center support bolt and discard. (Scheme 133) Remove snap ring. Using Gear Assembly Remover/Installer (J-38868), Adapter (J-21364-A) and slide hammer handle, remove gear assembly. (Scheme 132)
2. Remove low/reverse band and thrust washer. (Scheme 130) If necessary, select proper selective thrust washer based on end play measurements. See «END PLAY CHECKS»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e__end-play-checks). Set thrust washer aside for reassembly.
3. Remove output shaft seal retainer ring. Using slide hammer, remove output shaft seal.

Cleaning & Inspection

Thoroughly clean transmission case with solvent and dry using compressed air. Inspect transmission case for damage to band lugs, snap ring grooves, drive sprocket bearings, interconnected or damaged oil passages and servo bores. Inspect case for stripped threads in bolt holes or casting porosity. Check transmission case oil passages for restrictions or blockage. Blow compressed air through all transmission case oil passages. (Scheme 93) Repair or replace transmission case if necessary.

Scheme 93

DO NOT wash bands in solvent. Inspect each band assembly for heat damage, lining cracks and separation. Check band stop for damage and replace if necessary. If low/reverse band is replaced, recheck apply pin. See SERVO ASSEMBLIES under TRANSMISSION DISASSEMBLY.

Disassembly

Remove snap rings. Separate center support, output carrier, reaction carrier and parts of rear gear unit. (Scheme 94)

Using clutch spring compressor and adapter, compress intermediate clutch springs, and remove snap ring. Separate center support from intermediate clutch assembly. (Scheme 95)

1. Inspect output carrier, reaction carrier and reaction drum for damaged teeth, scoring or warpage. Check thrust bearing for damage. Using feeler gauge, check output carrier and reaction carrier pinion gear end play. (Scheme 96)and (Scheme 97).
2. End play should be.009-.024" (.23-.61 mm). Check for damage to reaction carrier internal gear. Ensure center support cup plug bleed hole opening is about.020" (.51 mm). (Scheme 98)

Center Support Recondition Procedure

If Bore Gauge (J-39919-2) fits into center support bolt hole, replace center support and bolt in order to avoid component damage. To determine if center support has not been previously reconditioned, insert bore gauge into center support bolt hole. If gauge does not fit, using Thread Reamer (J-39919-1), ream center support bolt hole to fit NEW service bolt. (Scheme 108)

Reassembly

Using Piston Installer (J-21363), install intermediate piston to center support. (Scheme 99) Reassemble center support and rear gear unit. (Scheme 100)- (Scheme 103). Install NEW oil seal rings to center support. Preheat oil seal rings in hot water prior to installation.

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Disassemble intermediate sprag clutch assembly. Discard locking ring. Remove direct clutch plates. (Scheme 104) Using clutch spring compressor and adapter, compress direct clutch springs, and remove snap ring.

Scheme 104

Inspect all parts for wear, cracks, burned plates and scoring; replace if necessary.

1. Reassemble intermediate sprag clutch. Install intermediate clutch race with grooves facing up. (Scheme 105) Install NEW locking ring. Ensure intermediate sprag rotates clockwise only. (Scheme 106)
2. Lubricate NEW piston seals with ATF and install. Using Clutch Piston Installers (J-21362 and J-38732), install piston into direct clutch housing. Reassemble direct clutch. Install apply plate (dished or waved). Starting with a steel plate, install clutch plates alternating between steel and composition. Direct clutch uses 5 steel plates, 5 composition plates and one dished or waved apply plate. (Scheme 104)and (Scheme 107).
3. Apply 80 psi (550 kPa) of air to reverse port. (Scheme 108) Air should bleed through direct clutch fluid port. Mount dial indicator to transmission case. Position dial indicator plunger on direct clutch piston. Zero dial indicator. Apply air pressure to direct port. Ensure piston seals do not leak. Direct clutch piston should move.050-.172" (1.27-4.37 mm).

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Disassemble forward clutch assembly. (Scheme 109) Using clutch spring compressor, compress and remove snap ring, and spring and retainer assembly. (Scheme 111) Remove clutch piston and seals from piston.

Inspect all clutch plates for cracks, wear, lining separation, pits or other signs of damage. Ensure forward clutch housing check ball is working. Inspect thrust washer for damage. Inspect clutch housing for damaged clutch hub, worn bushings or damaged oil seal rings.

1. Lubricate NEW piston seals with ATF and install. Using Clutch Piston Installers (J-21362-1 and J-38732-1), install piston into forward clutch housing. Reassemble forward clutch. (Scheme 109) Install waved plate. Install steel plate, and then alternate between composition plate and steel plate. Forward clutch uses 5 steel plates, 5 composition plates, and one waved or dished plate.
2. Place turbine shaft in soft-jawed vise. Install forward clutch assembly onto turbine shaft. Install dial indicator plunger onto forward clutch piston. Place index finger over one side of forward clutch passage on turbine shaft. Apply 80 psi (550 kPa) of air to turbine shaft air port. (Scheme 110) Ensure piston seals do not leak. Check forward clutch piston movement. Forward clutch piston should move.050-.172" (1.27-4.37 mm).

Scheme 109

Scheme 110

Scheme 111

Remove snap ring and backing plate. (Scheme 112) Remove clutch plates. Using clutch spring compressor, compress and remove snap ring and spring retainer. Remove clutch piston and seals from piston.

Inspect housing and clutch plates for damaged teeth, scoring or warpage. Ensure 4th clutch housing cup plug bleed hole opening is about .020" (.51 mm).

1. Using Piston Seal Protectors (J-38731-1, J-38731-2 and J-38731-3), install piston into 4th clutch housing. Reassemble 4th clutch assembly. (Scheme 112)
2. Install snap ring. Install steel plate, and then alternate between composition plate and steel plate. 4th clutch uses 4 steel plates and 4 composition plates. Ensure steel plate notches are indexed opposite 4th clutch bolt hole. Using feeler gauge, ensure clearance between backing plate and snap ring is.040-.100" (1.02-2.54 mm). (Scheme 113)

Scheme 112

Scheme 113

Remove overrun clutch housing from overdrive carrier assembly. (Scheme 114) Disassemble overrun clutch. (Scheme 115)and (Scheme 121). Using clutch spring compressor and adapter, compress spring retainer, and remove clutch piston. (Scheme 115) Disassemble overdrive assembly. (Scheme 121) If necessary, disassemble overdrive carrier assembly. (Scheme 120)

Scheme 114

Scheme 115

Inspect housing and clutch plates for damaged teeth, scoring or warpage. Inspect spring and spring retainer for damage. Inspect overdrive carrier assembly and turbine shaft for wear or damage. Replace if necessary. Mount dial indicator onto pinion gear. Ensure overdrive carrier pinion end play is.009-.024" (.23-.61 mm). (Scheme 117)

Turbine Shaft Seal Replacement

1. Remove oil seal rings from turbine shaft. Inspect seal ring grooves for nicks or burrs. Lubricate each oil seal ring. Place Seal Protector/Installer Kit (J-38736) on turbine shaft.
2. Quickly slide each seal into ring groove when protector is in position. Use seal driver from Kit (J-38736) to push ring over seal protector. Size seal with seal sizer from Kit (J-38736); gently twist seal sizer over each seal. Leave sizer in place.

1. Using Piston Seal Protector (J-38729), install piston into overrun clutch housing. (Scheme 116) Reassemble overrun clutch assembly. (Scheme 115)
2. Install snap ring. Install steel plate, and then alternate between composition plate and steel plate. Overrun clutch uses 3 steel and 3 composition plates. Install backing plate and snap ring. Using feeler gauge, ensure clearance between backing plate and snap ring is.033-.094" (.84-2.38 mm). (Scheme 118)
3. If necessary, reassemble overdrive carrier. (Scheme 119)- (Scheme 121). Install thrust washer into overdrive carrier. (Scheme 120) To complete reassembly, install turbine shaft and overdrive carrier to overrun clutch. (Scheme 114)and (Scheme 121). When turbine shaft and overdrive carrier are installed into transmission case, install thrust washer onto overrun clutch housing. Place a straightedge from oil pump mating surface to overrun clutch housing thrust washer. (Scheme 122) The 2 surfaces should be flush.

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Clean and air dry oil pump. Disassemble oil pump. (Scheme 123) Note location and direction of all components. Use caution when removing reverse boost valve snap ring. Regulator spring is under extreme pressure.

Inspect pump body for porosity, interconnected oil passages, damaged inner pump area surface or damaged machine facing. Check gears and bushings for damage.

1. Reassemble oil pump. (Scheme 123) Install oil pump gears into pump body with identification dots facing upward. Using straightedge, measure gear clearance between oil pump gears and pump body. Clearance should be.0008-.0028" (.020-.071 mm).
2. Ensure pump body mating surface is flat. Install pump cover onto body. Install cover bolts and hand tighten bolts. Install Alignment Pin (J-25025-1) into pump. Install and tighten oil pump Alignment Band (J-21368). (Scheme 125) Tighten oil pump attaching bolts.
3. To install TCC enable valve, compress spring into oil pump body, and insert a small rod into hole "A". (Scheme 124) Install spring retainer, and then remove small rod.

Scheme 123

Scheme 124

Scheme 125

MANUAL 2-1 & LOW/REVERSE SERVOS

Note. Manual 2-1 and low/reverse servos may also be referred to as front and rear servos.

Inspection & Reassembly

Inspect servo pistons and seals for damage or cracks. DO NOT remove seals unless replacement is required. Inspect springs for damaged coils. Replace all damaged parts, and reassemble servos. (Scheme 126)and (Scheme 127).

Scheme 126

Scheme 127

Inspect accumulator pistons and seals for damage or cracks. DO NOT remove seals unless replacement is required. Inspect springs for damaged coils. Replace all damaged parts, and reassemble accumulators. (Scheme 128)

Scheme 128

Thoroughly clean valve body and dry with compressed air. Cover bores when removing roll pins, as some valves are under pressure. Remove valves, springs and bushings, and place them on a clean surface in order removed. Note location and direction of all components. Remove solenoids. Remove blind hole roll pins with a drill bit. Remove servo pipe lip seals.

Clean valves, springs and bushings in solvent. Never 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.

To reassemble valve body assembly, reverse disassembly procedure. (Scheme 129)

Scheme 129

TRANSMISSION REASSEMBLY

Note. All selective thrust washer measurements taken during disassembly must be rechecked at appropriate reassembly stage. To aid in transmission reassembly, refer to the appropriate illustrations. (Scheme 145)- (Scheme 147).

CENTER SUPPORT & REAR GEAR UNIT

Note. Low/reverse band may also be referred to as rear band.

1. Install low/reverse band and thrust washer. Ensure band anchor pins engage band, and band assembly stop is in place. Install appropriate selective thrust washer. (Scheme 130)
2. Install center support spacer into groove above low/reverse band. Ensure spacer opening is place at the 9 o'clock position. (Scheme 131) Using Gear Assembly Remover/Installer (J-38868), Adapter (J-21364-A) and slide hammer handle, install gear assembly. (Scheme 132)
3. Install upper center support snap ring with beveled edge side up and opening at the 9 o'clock position. Using dial indicator, check rear unit end play. (Scheme 91) Rear unit end play should be.005-.025" (.13-.64 mm).
4. If rear unit end play is not correct, select proper size thrust washer. See «REAR END PLAY THRUST WASHER IDENTIFICATION»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e) table. If necessary, remove center support and rear unit to change selective thrust washer.
5. Using Center Support Aligner (J-23093), push center support splines counterclockwise against case splines (away from rear servo). Align center support with bolt hole. Using NEW bolt, install center support bolt. (Scheme 133) Tighten bolt to 32 ft. lbs. (43 N.m). Install rear oil cooler pipe fitting with NEW seal and tighten to 26 ft. lbs. (35 N.m).

REAR END PLAY THRUST WASHER IDENTIFICATION

Scheme 130

Scheme 131

Scheme 132

Scheme 133

INTERMEDIATE CLUTCH

1. Install intermediate wave plate with tangs facing downward. Install intermediate clutch plates, starting with steel plate, then alternating with composition plate (4 steel and 4 composition). (Scheme 134) Install backing plate with flat side down. Install snap ring at the 9 o'clock position.
2. Using feeler gauge, ensure clearance between clutch plates and backing plate is.040-.107" (1.02-2.72 mm). Install manual 2-1 band into case, and ensure proper alignment with anchor pin. Using Clutch Plate Aligner (J-24396), align intermediate clutch assembly.

Scheme 134

Apply air pressure into center support hole to hold intermediate clutch plates in place. Using Clutch Installer (J-38733), install direct clutch assembly. (Scheme 135) Using Clutch Installer (J-38358-A), install forward clutch assembly and thrust bearing. (Scheme 136)and (Scheme 145).

Note. Check installed height of speed sensor ring (on forward clutch housing). Top of speed sensor ring to oil pump gasket surface height should be 3.85-3.89" (98.0-99.0 mm).

Scheme 135

Scheme 136

1. Install 4th clutch support (without clutch plates) into transmission case. Using 40T Torx wrench, install NEW 4th clutch support bolt. (Scheme 137) Tighten bolt to 17-19 ft. lbs. (23-26 N.m).
2. Remove turbine seal sizer from turbine shaft. Install turbine shaft and overdrive assembly. (Scheme 114) Ensure assembly is fully seated. Place a straight edge from oil pump mating surface to overrun clutch housing thrust washer. (Scheme 122) The 2 surfaces should be flush. Install 4th clutch plates, starting with steel plate, then alternating with composition plate (4 steel and 4 composition). Install steel plates with narrow tang "V" notch at 1 o'clock position in housing. (Scheme 138) Install backing plate with flat side down. Install snap ring. (Scheme 139)

Scheme 137

Scheme 138

Scheme 139

1. Install Locating Pins (J-25025-1) at 12 o'clock and 5 o'clock positions. Install oil pump cover gasket. (Scheme 140) Install selective thrust washer. Using Handle (J-37789), install oil pump assembly. (Scheme 141) Ensure turbine shaft spins freely. Tighten oil pump bolts to 18 ft. lbs. (24 N.m).
2. Using dial indicator, check front unit end play. (Scheme 90) Front unit end play should be.004-.022" (.10-.56 mm). If front unit end play is not correct, select proper size thrust washer. See «OVERRUN CLUTCH HOUSING THRUST WASHER IDENTIFICATION»(/gmc/savana/i-1996-2002/remont/automatic-trans/#automatic-transmission-overhaul-4l80-e) table. If necessary, remove oil pump assembly to change selective thrust washer.

OVERRUN CLUTCH HOUSING THRUST WASHER IDENTIFICATION

Scheme 140

Scheme 141

Note. Low/reverse and manual 2-1 bands and servos may be referred to as front and rear bands and servos.

Install selected low/reverse band apply pin. If necessary, check low/reverse band apply pin using Band Apply Selector Pin (J-21370-10) and Band Apply Pin Gauge (J-38737). See SERVO ASSEMBLIES under TRANSMISSION DISASSEMBLY. Install manual 2-1 and low/reverse servo assemblies. (Scheme 126)and (Scheme 127).

1. Install parking pawl and manual linkage. (Scheme 86) Install check balls in case. Check ball No. 2 is only used on some models. (Scheme 85) Assemble and install accumulator assembly. (Scheme 128) Tighten accumulator assembly bolts in sequence. (Scheme 142)
2. Install valve body assembly and TFP position switch. Tighten TFP position switch bolts to 97 INCH lbs. (11 N.m) in alphabetical sequence. (Scheme 143) Tighten valve body bolts in a spiral pattern in numerical order. (Scheme 144) Install lube pipe and wiring harness. (Scheme 143) Install oil pan and oil filter. (Scheme 83)

SPEED SENSORS & CASE EXTENSION

Install and secure torque converter. Install case extension. Install speed sensors. (Scheme 82)

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

TRANSMISSION SPECIFICATIONS

TRANSMISSION SPECIFICATIONS

See also:
• REMOVAL & INSTALLATION
• CLUTCH & BAND APPLICATION
• ROAD TEST
• HYDRAULIC PRESSURE TESTS
• TROUBLE SHOOTING
• END PLAY CHECKS
• SERVO ASSEMBLIES