Automatic Transaxle Overhaul & Testing - 4t60-e Oldsmobile Achieva I final

APPLICATION

TRANSMISSION APPLICATIONS

IDENTIFICATION

All transaxles have a metal identification plate attached to the rear face of transaxle case. (Scheme 24) Transaxle RPO code is M13.

Scheme 24

DESCRIPTION

Hydra-Matic 4T60-E transaxle is a fully automatic 4-speed unit consisting primarily of a 3-element hydraulic torque converter and converter clutch. Transaxle uses a variable capacity vane-type oil pump to supply all hydraulic pressure needed for operation.

Multiplied torque from torque converter is transferred to transaxle by a sprocket and drive link chain assembly. Other internal components consist of 4 multiple-disc clutches, a roller clutch, a sprag clutch, 3 bands and a compound planetary gear set. Final drive gear and differential assemblies are an integral part of transaxle.

Transaxle uses 2 electronic shift solenoids, controlled by the Powertrain Control Module (PCM), to switch hydraulic pressure on or off. Another electronic solenoid controls Torque Converter Clutch (TCC) lock-up. A Pulse Width Modulated (PWM) solenoid is used to control rate of TCC apply.

LUBRICATION & ADJUSTMENTS

See TRANSMISSION SERVICING - A/T article in the AUTOMATIC TRANS SERVICE section.

ON-VEHICLE SERVICE

The following components can be serviced without removing transaxle from vehicle.

1. Case Side Cover Pan
2. Converter-To-Flexplate Bolts
3. Cooler Lines
4. Drive Axles
5. Filler Pipe
6. Final Drive
7. Forward Servo
8. Reverse Servo
9. Scavenger Oil Scoop
10. Shift Control Cable
11. Solenoids
12. Speed Sensor
13. Thermal Element
14. Transaxle Pan
15. Transaxle Filter
16. Vacuum Modulator
17. Control Valve Assembly
18. Wiring Harness
19. 1-2 Servo
20. 1-2 Or 3-4 Accumulator Assemblies

CONTROL VALVE ASSEMBLY

See TRANSMISSION SERVICING-A/T article in the AUTOMATIC TRANS SERVICE section.

DRIVE AXLE SHAFTS

See appropriate AXLE SHAFT article in the POWERTRAIN section.

OIL COOLER FLUSHING

1. If available, fill Line Flusher (J-35944) with solution, and install oil cooler and line flusher to top transaxle cooler line on transaxle. Follow tool manufacturer's instructions to flush oil cooler and cooler lines.
2. If line flusher 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 testing and diagnostic procedures of electronic components, see AUTO TRANS DIAGNOSIS 4T60-E article in the AUTO TRANS DIAGNOSIS section.

Note. For clutch and band applications, refer to table CLUTCH & BAND APPLICATION under TROUBLE SHOOTING.

QUICK CHECK

1. Check level and condition of transaxle fluid. Check PCM memory for stored Diagnostic Trouble Codes (DTCs). See «AUTO TRANS DIAGNOSIS 4T60-E»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-diagnosis-4t60-e) article in the AUTO TRANS DIAGNOSIS section. If no DTCs are present, go to next step. If DTCs are present, diagnose and repair all PCM-related trouble codes. Clear PCM trouble code memory.
2. Perform road test. See «ROAD TEST»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e__road-test) under TESTING. During road test, record shift points. If shift point timing or shifting is incorrect, go to «AUTO TRANS DIAGNOSIS 4T60-E»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-diagnosis-4t60-e) article in the AUTO TRANS DIAGNOSIS section.
3. If shift(s) is too harsh or too soft, see «HYDRAULIC PRESSURE TESTS»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e__hydraulic-pressure-tests) under TESTING. For specific complaints, see appropriate condition(s) listed under SYMPTOM DIAGNOSIS under TROUBLE SHOOTING.

SYMPTOM DIAGNOSIS

Note. For transaxle component locations (Scheme 25)

Oil Out Of Vent Or Foaming

Transaxle overfilled. Oil contaminated with antifreeze or engine overheating. Oil filter seal damaged or missing. Thermo element in case does not close when hot, incorrect pin height or thermo element incorrectly installed. Modulator "O" ring incorrectly installed or damaged. Drive sprocket support drain back holes plugged.

High Or Low Line Pressure

Incorrect oil level. Vacuum line leaking, pinched, disconnected or cut. Modulator diaphragm damaged. Modulator valve nicked, scored or stuck. Oil pump assembly seals or vanes damaged or slide stuck. Pump drive shaft damaged. Pressure regulator valve spring damaged or pressure regulator valve nicked or scored. Pressure relief valve spring damaged or ball missing. Check balls missing in control valve assembly. Pump or case cover leaking (bolts loose).

Delayed Engagement

Low fluid level. Oil cooler check ball not seating. Reverse servo or forward servo seals cut or damaged. Cut or damaged input housing piston seal. Damaged forward servo seals or servo assembly. Input clutch outer piston seal damaged.

No Drive In "D"

1. Low oil level or line pressure. Manual linkage misadjusted or disconnected. Piston or seal damaged in forward servo assembly. Drive axles disengaged. Leaking or damaged 2-1 servo oil pipe seals. Damaged oil pump drive shaft or pump assembly. Incorrect No. 3 check ball location. Torque converter stator roller clutch damaged. Input clutch accumulator piston seal damaged. Drive link assembly damaged, drive link chain broken or sprockets and bearings damaged.
2. Input clutch assembly plates burned, clutch plates missing, check ball capsule leaking or missing. Input piston seals cut or damaged, or shaft feed passages blocked. Damaged or incorrectly assembled input sprag or input sun gear assembly. Burned 3rd roller clutch (due to lack of lubrication), oil lube pipe leaking or damaged.
3. Input carrier and reaction carrier assembly pinions, internal ring gear or sun gear damaged. Output shaft damaged or drive axles incorrectly assembled into differential. Burned forward band assembly or band out of position. Parking pawl spring broken. Damaged final drive assembly or final drive sun gear, side gears, pinion gears or internal ring gear.

Slips In "D"

Low fluid level. Vacuum line pinched or cut. Damaged modulator. Low line pressure. Oil pump assembly seals or vanes damaged or slide stuck. Modulator valve stuck or binding. Damaged forward servo assembly or leaking servo piston seal. Oil filter screen plugged. Leaking or damaged servo pipe seals. Torque converter stator roller clutch not holding. Input clutch accumulator piston or input shaft seals damaged. Leaking ball capsule or damaged input clutch assembly seals. Check for problem with solenoid "A" or "B". Check for switched wires between TCC and solenoid "B".

No 1-2 Shift (1st Gear)

Check for binding or stuck 1-2 shift valve. Spacer plate or gaskets mispositioned or damaged. Drive sprocket support oil sealing rings damaged. Clutch plates in 2nd clutch assembly damaged. Piston or piston seals in 2nd clutch damaged. Incorrectly assembled 2nd clutch. Missing or damaged check ball capsule in 2nd clutch housing. Reverse reaction drum splines damaged or reverse reaction drum plate missing.

Harsh Or Soft 1-2 Shift

High or low line pressures. Damaged 1-2 accumulator piston seals or piston springs missing. Accumulator cover bolts improperly tightened or gaskets mispositioned. Accumulator valve in control valve assembly stuck. Incorrect No. 2 check ball location. Damaged seals on driven support sprocket.

1-2 Shift Shudder

Damaged 2nd clutch or driven sprocket support.

No 2-3 Shift (1st & 2nd Gears)

Check for DTCs. Diagnose and repair as necessary. Solenoid "B" stuck on. Dirt in solenoid, PCM signal to solenoid "B" grounded or signal return wire shorted to ground.

1-4 Shift (Misses 2nd & 3rd Gears)

Check for DTCs. Diagnose and repair as necessary. Solenoid "A" stuck on. Dirt in solenoid, PCM signal to solenoid "A" grounded or signal return wire shorted to ground.

2-3 Shift Only

Check for DTCs. Diagnose and repair as necessary. Failed solenoid "A" (solenoid off). Dirt in filter, PCM not grounded, leaking "O" ring, no supply voltage to solenoid "A" or wire disconnected.

1-2-4 Shift (No 2-3 Shift)

Stuck 2-3 shift valve or 3-2 manual shift valve. Mispositioned or damaged channel plate gasket. Blocked 3rd clutch port in driven sprocket support. Seals damaged or leaking in input shaft. Burned 3rd clutch assembly. Damaged or incorrectly assembled 3rd roller clutch assembly.

Harsh Or Soft 2-3 Shift

Low or high oil pressures. Mispositioned No. 4 check ball causing soft shift. Leaking 2-3 accumulator piston. Missing No. 9 check ball causing harsh shift.

Early Or Late 2-3 Shift

Wrong PROM. Check for possible service bulletins.

3-4 Shift (Misses 1st & 2nd Gears)

Check for DTCs. Diagnose and repair as necessary. Solenoid "B" stuck off. Dirt in solenoid, "O" ring leaking, PCM signal to solenoid "B" grounded or signal return wire shorted to ground.

No 3-4 Shift

Check for manual shift linkage out of adjustment. Sticking 3-4 shift valve. Splines on 4th clutch shaft damaged. Burned 4th clutch assembly plates, damaged piston seals or incorrect number of clutch plates.

Harsh Or Soft 3-4 Shift

High or low line pressures. Accumulator cover bolts improperly tightened. Damaged accumulator seals or pistons. Check for stuck 3-4 accumulator valve in control valve assembly or missing No. 10 check ball.

Early Or Late 3-4 Shift

Wrong PROM. Check for possible service bulletins.

No Reverse

1. Low oil pressure. Reverse servo or apply pin incorrectly assembled, piston or seal damaged. Damaged oil pump drive shaft or oil pump assembly. Input clutch accumulator piston seal damaged. Drive link assembly damaged or drive link chain broken. Burned, damaged or mispositioned reverse band. Input clutch assembly plates burned, clutch plates missing or check ball capsule leaking or missing.
2. Input piston seals cut or damaged, or shaft feed passages blocked. Damaged or incorrectly assembled input sprag or input sun gear assembly. Reverse reaction drum splines damaged. Burned 3rd roller clutch (due to lack of lubrication), or oil lube pipe leaking or damaged.
3. Input carrier and reaction carrier assembly pinions, internal ring gear or sun gear damaged. Output shaft damaged or drive axles incorrectly assembled into differential assembly. Damaged solenoid "A" or TCC solenoid. Parking pawl spring broken. Damaged final drive assembly or final drive sun gear, side gears, pinion gears or internal ring gear.

Locked In Reverse

Damaged parking pawl binding on final drive internal gear.

Slips In Reverse

Low oil pressure. Reverse servo seal damaged. Reverse reaction drum splines stripped.

Vehicle Moves In Park

Manual linkage damaged or disconnected. Broken final drive parking pawl spring, parking pawl or parking pawl gear in final drive internal gear assembly. Park actuator spring damaged.

Harsh Neutral-To-Drive Engagement

Engine idle too high. Loss of vacuum due to damaged lines or modulator. Reverse servo cushion spring weak or broken. Check ball No. 5 missing (also harsh engagement in Reverse). Check ball No. 6 is missing. Control valve assembly spacer plate mispositioned. Thermal element does not close when warm. Reverse servo apply pin too long.

Vehicle Starts In 2nd Gear

Stuck 1-2 shift valve. 2nd clutch housing and drum scored or has hot spots. Reverse band fiber burned. No. 5 check ball missing or out of position. Incorrect servo cushion spring or damaged spring.

Harsh Reverse

Scored 2nd clutch housing. Burned reverse band fiber. Check for missing or mispositioned check ball No. 5, or damaged or wrong servo cushion spring.

No Engine Breaking In Manual 2nd Or Low

Burned 1-2 band. Apply pin not engaging 1-2 band. Apply servo seals leaking, servo cover loose or piston binding in bore.

Harsh 4-3 Downshift

Missing No. 10 check ball in control valve assembly. 3-4 accumulator valve stuck or 3-4 accumulator seal cut.

Harsh 3-2 Downshift

No. 9 check ball in control valve assembly missing. 2-3 accumulator valve stuck or 2-3 accumulator seal cut.

Harsh 2-1 Downshift

Wrong spacer plate, stuck 1-2 accumulator valve or cut 1-2 accumulator seal.

Note. PCM controls TCC, PWM solenoid and shift solenoids "A" and "B".

No Converter Clutch Apply

Verify proper PCM operation and vehicle wiring. Engine coolant temperature sensor damaged. Damaged wiring harness or pinched wires. Solenoid inoperative. Converter clutch shift valve in control valve assembly stuck. Converter clutch apply valve stuck. Solenoid "O" ring leaking or screen blocked.

Torque converter external leaks at hub weld area, or fluid unbalanced or contaminated. Turbine shaft seals damaged. Oil pump drive shaft seal damaged. Channel plate converter clutch blow-off check ball not seated or damaged.

Converter Clutch Does Not Release

PCM-controlled TCC solenoid does not exhaust. Control valve assembly converter clutch apply valve stuck in apply position. TCC orifice screen missing.

Converter Clutch Stuck On In 3rd & 4th

TCC solenoid stuck on. Dirt in TCC solenoid. Wire between TCC solenoid and PCM shorted to ground.

Converter Applied With Maximum Pressure

PWM solenoid always off. Dirt in solenoid. Leaky "O" ring. No voltage to PWM solenoid. Open wire or no apply signal from PCM.

Converter Clutch Apply Rough, Slips Or Shudders

Control valve assembly converter clutch regulator valve stuck. Turbine shaft seals damaged or missing. Converter clutch blow-off check ball not sealed or damaged. Damaged channel plate converter clutch accumulator piston or seal (if equipped). Spring damaged. Wrong blow-off spring. Seals damaged or missing. Defective converter clutch.

No TCC

Check for DTCs. Diagnose and repair as necessary. Check the following solenoids and switches for faulty operation, dirt or binding: TCC solenoid, PWM solenoid, brake switch, PRNDL (transaxle range switch) and engine coolant temperature sensor. Check same solenoid and switch circuits for open or shorted wires between voltage supply or PCM.

Scheme 25

CLUTCH & BAND APPLICATION

ELECTRONIC SELF-DIAGNOSTICS & ELECTRONIC TESTING

Note. See AUTO TRANS DIAGNOSIS 4T60-E article in the AUTO TRANS DIAGNOSIS section.

ROAD TEST

Note. Before road testing vehicle, engine and transaxle must be at operating temperature. Torque converter clutch will not engage if engine coolant has not reached operating temperature of 140°F (60°C).

Gear Selector Position "D" (Overdrive)

1. With gear selector in "D" (overdrive) position, steadily increase throttle pressure to accelerate vehicle. Note shift speed engagement points in 2nd gear, 3rd gear and overdrive gear. Use «SHIFT SPEED SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) tables as a reference for proper shift speeds. Also note Torque Converter Clutch (TCC) engagement point while in 3rd gear or Overdrive. See «TORQUE CONVERTER CLUTCH APPLICATION»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) table. NOTE: Shift points may vary due to engine operating conditions. PCM interprets numerous electronic signals from various sensors on vehicle. This may cause a variation in shift points.
2. At vehicle speeds of 40-55 MPH, quickly depress accelerator to half-open position (part throttle detent downshift). TCC should release, and transaxle should immediately downshift to 3rd gear.
3. At vehicle speeds of 40-55 MPH, quickly depress accelerator to wide open position (full throttle detent downshift). TCC should release, and transaxle should immediately downshift to 2nd gear.
4. At vehicle speeds of 40-55 MPH, release accelerator pedal while moving gear selector to "3" (third gear) position. TCC should release, transaxle should downshift into 3rd gear, and engine braking should slow vehicle.
5. Move gear selector to "D" (overdrive) position, and accelerate to 40-45 MPH. Release accelerator pedal while moving gear selector to "2" (2nd gear) position. TCC should release, transaxle should downshift to 2nd gear immediately, and engine braking should slow vehicle.
6. Move gear selector to "D" (overdrive) position, and accelerate to 25 MPH. Release accelerator pedal while moving gear selector to "1" (1st gear) position. TCC should release, transaxle should downshift to 1st gear and engine braking should slow vehicle.
7. With gear selector in "D" (overdrive) position, accelerate vehicle to overdrive gear with TCC applied. Release accelerator pedal, and lightly apply brakes. TCC should release. Note speeds at which vehicle downshifts.

Note. Downshift speed information not available.

Gear Selector Position "3" (3rd Gear)

With vehicle stopped, move gear selector to "3" (3rd gear) position and steadily increase throttle pressure to accelerate vehicle. Note speeds at which vehicle shifts into 2nd and 3rd gears. See SHIFT SPEED SPECIFICATIONS table. Also note when TCC engages while in 3rd gear. See TORQUE CONVERTER CLUTCH APPLICATION table.

Gear Selector Position "2" (2nd Gear)

With vehicle stopped, move gear selector to "2" (2nd gear) position. Accelerate vehicle and note speed at which vehicle shifts from 1st gear to 2nd gear. Accelerate vehicle to 25 MPH. Transaxle should not shift into 3rd gear, and TCC should not engage.

Gear Selector Position "1" (1st Gear)

With vehicle stopped, move gear selector to "1" (1st gear) position. Accelerate vehicle to 15 MPH. Transaxle should not upshift, and TCC should not engage.

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 tachometer to engine, hand-held vacuum pump to vacuum modulator and oil pressure gauge to line pressure test port. (Scheme 24) Check line pressure at specified engine RPM. See «LINE PRESSURE SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) table.

Note. Hydraulic pressure is controlled by pump output and regulated by pressure regulator valve. Line pressure is boosted by reverse boost valve when gear selector is in "R" and "D1" positions. Line pressure should increase with throttle opening due to decrease in engine vacuum to modulator.

Minimum Line Pressure Check

Start engine, and apply 18 in. Hg to vacuum modulator. Record line pressure readings in all gear selector positions with engine running at specified RPM, and compare recorded pressures to specifications. See LINE PRESSURE SPECIFICATIONS table. If recorded pressure is incorrect, see HIGH OR LOW LINE PRESSURE under TROUBLE SHOOTING .

Full Line Pressure Check

Release vacuum applied to modulator. Record line pressure readings in all gear selector positions with engine running at specified engine RPM. Compare recorded pressures to specifications. See LINE PRESSURE SPECIFICATIONS table. If pressure recorded is incorrect, see HIGH OR LOW LINE PRESSURE under TROUBLE SHOOTING .

SHIFT SPEED SPECIFICATIONS

TORQUE CONVERTER CLUTCH APPLICATION

LINE PRESSURE SPECIFICATIONS

REMOVAL & INSTALLATION

See TRANSMISSION REMOVAL & INSTALLATION article in the AUTO TRANS SERVICING section.

INSPECTION

Torque converter must be replaced for any of the following reasons.

1. Damage To 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. Overheating (Torque Converter Is Blue)
9. Engine Coolant Contamination
10. Excessive End Play

STALL SPEED TEST

Note. Information not available.

NOISE TEST

1. Torque converter whine is usually noticed when vehicle is stopped and transaxle is in Reverse or Drive. Whine will increase when engine RPM is increased and will stop when vehicle is moving or when torque converter clutch is applied. Stall test is 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 transaxle in Drive. Depress accelerator to about 1200 RPM for less than 6 seconds. DO NOT depress accelerator for more than 6 seconds or transaxle damage may occur. 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

1. Torque converter stator roller clutch can either remain locked up at all times or freewheel in both directions. If stator is freewheeling at all times, vehicle tends to have poor acceleration from a stop. Vehicle may act normal at speeds above 30-35 MPH.
2. If poor acceleration is noted, ensure exhaust system is not blocked, engine timing is correct and transaxle is in 1st gear when starting from a stop. If stator is locked up at all times, performance from a stop appears normal. Engine RPM and acceleration is limited at high speeds. Engine may overheat from this condition.
3. A visual inspection of torque converter may reveal converter is Blue from overheating. If torque converter has been removed from vehicle, stator roller clutch can be checked by inserting 2 fingers into splined inner race of roller clutch and trying to turn race in both directions. Inner race should turn freely clockwise but should not turn or should be difficult to turn counterclockwise.

END PLAY CHECK

Mount Torque Converter End Play Fixture (J-35138) and Dial Gauge (J-8001) on torque converter to check end play. End play should be 0-.020" (0-0.51 mm). (Scheme 26)

Scheme 26

* PLEASE READ THIS FIRST *

Note. On February 2, 1995, manufacturer introduced a redesigned 2-1 servo seal. Previous design seal (.066") and NEW design seal (.132") are both included in Service Package (24204817). Seal is located above 2-1 servo cover. (Scheme 28) Seal pocket in transaxle case is machined deeper to support NEW design. Seal is twice as tall as previous design seal and is a square cut design. Seal thickness and outside diameter did not change. Seal retains fluid in forward servo circuit to apply forward band. Seals are NOT interchangeable.

REAR SECTION

Thoroughly clean transaxle exterior. Drain fluid, and remove torque converter. Place transaxle in holding fixture. Remove vehicle speed sensor and rear extension housing. (Scheme 27)

LOWER SECTION

Remove bottom oil pan, oil filter, accumulator cover with 2-1 servo feed and return pipes. Remove modulator and modulator valve. (Scheme 27) Check modulator with known good modulator and Tester (36619). If necessary, replace modulator. Remove all retainers, gaskets, pipes, 2-1 manual servo assembly and accumulator piston assemblies from bores. Accumulator springs are transaxle model specific. DO NOT interchange springs. (Scheme 27)and (Scheme 28).

Scheme 27

Scheme 28

SERVO ASSEMBLIES

Apply inward pressure to top of reverse servo cover, and remove cover retaining ring. Remove reverse servo cover and reverse servo assembly from case. (Scheme 27) Remove forward servo cover bolts. Remove servo cover and forward servo assembly from case. (Scheme 27)

OIL PUMP & CONTROL VALVE ASSEMBLY

1. Remove case side cover attaching bolts, nuts and washers. Remove case side cover, seal and gaskets. Disconnect wiring harness from solenoids, temperature sensor and case connector. Remove wiring harness. (Scheme 29)
2. Remove linkage and bracket from control valve assembly. Remove oil pump assembly bolts to remove oil pump from control valve assembly. (Scheme 31) Remove servo pipe retainer bolt and retainer plate. Remove remaining mounting bolts from control valve assembly. (Scheme 30) Remove control valve assembly from channel plate.
3. Remove spacer plate and gaskets. Remove oil pump drive shaft. Remove 6 check balls between channel plate and spacer plate. (Scheme 32) Remove 4 check balls between spacer plate and control valve assembly. (Scheme 33) Remove solenoid screens. (Scheme 29)

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

CHANNEL PLATE ASSEMBLY & 4TH CLUTCH

1. Remove oil dam from cavity above 4th clutch assembly. (Scheme 27) Disconnect manual valve link from manual valve, and pull spring back. (Scheme 34) Place detent lever in Park position for clip removal. Remove channel plate attaching bolts. (Scheme 35) Remove channel plate and channel plate gaskets. (Scheme 34)
2. Remove 3-4 accumulator piston assembly and TCC blow-off cup plug and spring. Remove 4th clutch plates and apply plate. Remove 4th clutch hub thrust washer. Remove 4th clutch hub and shaft assembly. (Scheme 36)

Scheme 34

Scheme 35

Scheme 36

FINAL DRIVE CARRIER ASSEMBLY

1. Rotate output shaft until "C" ring opening is visible from beneath lower tapered end of transaxle case. Using "C" Ring Remover/Installer (J-34757), push "C" ring partially off shaft, then rotate shaft and remove ring with needle-nose pliers. Ring can also be removed with 2 long thin screwdrivers. Remove output shaft.
2. Check final drive end play. See «FINAL DRIVE CARRIER ASSEMBLY»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) under COMPONENT DISASSEMBLY & REASSEMBLY. (Scheme 41) Remove final drive carrier assembly and selective thrust washer and bearing. Remove final drive internal gear snap ring and internal gear from case. (Scheme 52)

DRIVE LINK ASSEMBLY

Note. (Scheme 52)for exploded view of all internal components (from drive link support to final drive carrier assembly). (Scheme 53)for thrust washer and bearing locations. (Scheme 54)for lip seal locations.

1. Remove "O" ring seal from turbine shaft. (Scheme 36) Remove turbine shaft drive sprocket, driven sprocket and drive link chain together as an assembly. Note position of master link on drive link chain. Link is a different color then other links. Master link may be Bronze and be facing up or down. Original link MUST be installed in same direction as removed during installation. NEW link must be installed with colored link facing up.
2. Remove drive sprocket and driven sprocket thrust washers from between sprockets and channel plate. Remove chain scavenging scoop and driven sprocket support with 4th clutch thrust washer. (Scheme 36)

INPUT & 2ND CLUTCH ASSEMBLIES

1. Using Final Drive/Clutch Assembly Remover/Installer (J-33381), remove 2nd clutch and input shaft clutch housings as an assembly. (Scheme 37) Remove reverse band if it did not come out with 2nd clutch housing.
2. Separate 2nd clutch housing from input clutch housing. Remove thrust washer and thrust bearing from input housing. Install input clutch housing and shaft assembly into transaxle case. Install Loading Tool (J-26958) to transaxle case. (Scheme 38)
3. Install differential thrust washer, thrust bearing and case extension. Using feeler gauge, measure input clutch housing end play using End Play Gauge (J-33386). Record measurements for proper end play clearances during reassembly. (Scheme 38)
4. Fit proper selective thrust washer and measure clearance. Record measurement, and set aside proper selective washer for reassembly. Remove transaxle components and loading tool. For thrust washer identification and sizes, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) table under TRANSAXLE REASSEMBLY.

Scheme 37

Scheme 38

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. Remove reaction carrier, reaction sun gear/drum assembly and 1-2 band. Remove reaction sun gear thrust bearing and final drive sun gear shaft. Remove forward band. DO NOT clean bands in solvent.

Cleaning & Inspection

Clean transaxle case thoroughly with solvent, and then air dry. Inspect transaxle case for damage to band lugs, snap ring grooves and drive sprocket bearings. Check for interconnected or damaged oil passages and servo bores. Inspect case for stripped threads in bolt holes or casting porosity. Repair or replace case if necessary.

Drive Sprocket Support

1. If removal of drive sprocket bearing from case is necessary, use Bearing Puller (J-26941) and Slide Hammer (J-23907). (Scheme 39) Remove support bearing, and install NEW bearing with Bearing Installer (J-28677) and Driver Handle (J-8092).
2. If drive sprocket support replacement is necessary, remove attaching bolts and remove support. Install NEW support, and tighten attaching bolts to specification. See «TORQUE SPECIFICATIONS»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e__torque-specifications).

Note. DO NOT remove these parts unless replacement is necessary.

Manual Shaft, Detent Lever & Actuator Rod

If manual shaft, detent lever or actuator rod removal is necessary, remove pin and lock nut from manual shaft. Remove actuator rod from detent lever. Remove retaining pin from case. Remove actuator rod assembly from case. Remove "O" ring from actuator rod guide. (Scheme 36)

Scheme 39

Disassembly & Inspection

1. Inspect final drive internal gear for damaged teeth, worn bearing surfaces, broken parking pawl spring or damage to parking pawl. Inspect sun gear, thrust bearings, parking gear and speed sensor rotor for wear or damage.
2. Check final drive carrier pinion gears for excessive end play. Use a feeler gauge and measure end play between carrier and pinion gear thrust washer. End play should be.009-.025" (.24-.63 mm).
3. Using a pin punch, drive differential pinion shaft retainer pin from carrier. Remove pinion shaft, pinion and side gears, and thrust washers. (Scheme 40) Inspect all parts for damage or abnormal wear. Inspect final drive sun gear shaft for damaged splines or journals.

Reassembly

1. Assemble differential side gears and thrust washers into carrier. Using petroleum jelly, stick thrust washers onto pinion gears. Assemble pinion gears and washers into carrier.
2. Slide pinion shaft through both pinion gears for alignment, then remove shaft. Rotate pinion gears into position, then install pinion shaft. Tap retaining pin into position using a plastic hammer.
3. Tap speed sensor rotor (if removed) into position using soft mallet. Install sun gear with stepped side facing parking gear. Assemble parking gear on sun gear.
4. Inspect carrier-to-case selective thrust washer for damage. Install thrust washer onto carrier hub. Install thrust bearing onto thrust washer and retain with petroleum jelly.
5. Assemble thrust bearing on internal gear. Install internal gear to case and install snap ring. Move detent lever out of "P" position. Install final drive carrier assembly into case.
6. To measure final drive end play, install dial indicator so pointer contacts Adapter (J-26958-10). (Scheme 37) Lift speed sensor rotor with Snap Ring Remover (J-28585), and read dial indicator.
7. Correct end play is.005-.025" (.13-.63 mm). If necessary, adjust end play with selective carrier-to-case thrust washer. See CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES table.

CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES

Scheme 40

Scheme 41

Inspection & Reassembly

Inspect final drive sun gear shaft for damaged splines or journals. (Scheme 52) Install thrust bearing. Install final drive sun gear shaft into final drive, ensuring splines engage with parking gear and sun gear.

DO NOT wash bands in solvent. Inspect 1-2 and forward band assembly for heat damage, lining cracks and separation. Check band stop for damage and replace if necessary.

Inspect reaction carrier and reaction drum for damaged teeth, scoring or warpage. Check thrust bearing for damage. Using a feeler gauge, check reaction carrier pinion gear end play. End play should be .009-.030" (.23-.77 mm). Check for damage to reaction carrier internal gear.

1. Install reaction sun gear-to-final drive internal gear thrust bearing, positioning inner race against internal gear. Assemble reaction sun gear and drum assembly onto final drive internal gear.
2. Install reaction carrier-to-sun gear thrust bearing, positioning inner race against reaction carrier. Retain bearing with petroleum jelly. Install reaction carrier, rotating carrier until pinions engage sun gear.

Check input carrier pinion gears for proper end play. Pinion gear end play should be .009-.030" (.23-.77 mm). Inspect internal gear and pinion gears for worn or damaged teeth, and ensure pinions rotate freely. Inspect thrust bearing for damage (thrust bearing cannot be removed from carrier).

Install thrust bearing with inside race against carrier. Retain thrust bearing with petroleum jelly. Install input carrier into case, and rotate into position.

Inspect reverse reaction drum for damaged teeth and distortion. Install reverse reaction drum, ensuring spline teeth engage input carrier. DO NOT wash reverse band in solvent. Inspect reverse band assembly for damage and replace if necessary.

Disassembly

Remove spiral lock ring from inner race and retainer assembly. Remove 3rd sprag and input sprag assemblies from inner race and retainer assembly. Disassemble inner race and retainer assembly, and input sun gear spacer from input sun gear. (Scheme 42) Remove input sprag assembly from outer race. Note sprag cage direction for installation reference. Remove end bearing from outer race.

Scheme 42

Inspect 3rd sprag outer race for scoring and wear. Inspect assemblies for damaged rollers and springs. Install any loose roller by depressing spring and inserting roller. Inspect input sprag inner and outer races for damage. Check sprag assembly for damaged sprags or cages. Number of sprags may vary. Check sprag cage for distortion or broken tabs. Inspect input sun gear splines and bushing for damage.

1. Position 3rd sprag outer race on bench with lube dam side down. Install center bearing into 3rd clutch outer race. Lip on sprag cage should be in up position. Install end bearing into outer race.
2. Position input sprag outer race flat on bench with lube dam side up. Install end bearing into outer race. Install 3rd sprag assembly into outer race, noting direction of sprag assembly. Install sun gear spacer onto input sun gear. Install input sprag and 3rd sprag assemblies onto inner race. Install retainer onto inner race. (Scheme 42)
3. Install NEW spiral lock ring onto sprag inner race. Spiral lock ring must be seated in groove on inner race. Tabs and slots on lock ring must lock. Install 3rd sprag and input sprag assemblies onto input sun gear. Ensure input sprag and 3rd sprag assemblies rotate in correct direction. (Scheme 43)

Scheme 43

1. Remove input shaft thrust washer and input clutch backing plate snap ring. Remove input clutch backing plate. Remove input clutch steel and composition plates. Remove input clutch apply plate.
2. Remove 3rd clutch backing plate snap ring and backing plate. Remove 3rd clutch steel and composition plates. (Scheme 52) Remove 3rd clutch sprag retainer snap ring. Using Clutch Spring Compressor (J-23327) and Adapter (J-25018-A), compress and remove spring retainer.
3. Remove 3rd clutch piston from housing. Remove 3rd clutch piston inner seal from shaft. Compress piston housing, and remove snap ring. Remove "O" ring. Remove spring and retainer assembly. Remove input clutch piston and inner seal.

Inspect all clutch plates for cracks, wear, lining separation, pits or other signs of damage. Inspect thrust washer for damage. Inspect input clutch housing and shaft for interconnected oil passages, damaged clutch hub, worn bushings, or damaged 3rd clutch shaft seal or oil seal rings.

Input Shaft Seal Replacement

1. Remove solid oil seal rings from input shaft. Inspect seal ring grooves for nicks or burrs. Lubricate each oil seal ring, and position them one at a time on Seal Protector (J-34741-1). (Scheme 44)
2. Quickly slide each seal into ring groove when protector is in position. Use Seal Driver (J-34741-2) to push ring over seal protector. Size seal with Seal Sizer (J-34741-3). Gently twist seal sizer over each seal. Leave sizer in place until installation.

Retainer & Ball Assembly Replacement

Remove retainer and ball assembly from housing using a 1/4" drift. Install NEW retainer and ball assembly.

Piston Seal Replacement

Remove seals from input clutch piston or 3rd clutch piston. Lubricate NEW seals with ATF, and install seals.

1. Lubricate input clutch piston inner seal with ATF, and install seal using Seal Protector (J-37361). Assemble input piston into input housing. Assemble "O" ring seal onto input shaft.
2. Install spring retainer and guide in piston. (Scheme 52) Install 3rd clutch piston housing into input housing. Using spring compressor, compress 3rd clutch housing, and install snap ring. Install 3rd clutch inner seal. Install 3rd clutch piston into housing. Compress 3rd clutch spring retainer, and install snap ring.
3. Install wave plate. Assemble 3rd clutch plates; start with steel plate, and then alternate between composition and steel plates. Install 3rd clutch backing plate with side stamped UP facing up. Install snap ring.
4. Install input clutch apply plate into input housing with notched side of teeth facing down. Install waved plate. Assemble input clutch plates; start with steel plate, and then alternate between composition and steel plates. Install input clutch backing plate with tapered teeth side facing up.
5. Install snap ring. Apply air pressure to oil passages in input shaft, and check for proper operation of clutch assembly. Air pressure must not exceed 20 psi (1.4 kg/cm 2 ). (Scheme 45)

Scheme 44

Scheme 45

Remove snap ring and backing plate. (Scheme 46) Remove clutch plates, waved plate and snap ring. Remove apply ring and return spring assembly. Remove piston.

1. Inspect steel and composition plates for wear, lining separation, pitting or damage. Inspect apply ring and return spring for damage. Inspect piston and piston seals for damage.
2. Inspect 2nd clutch housing for damaged inner piston seal. Inspect for damaged bushings and spline teeth. Check for scored band surface. Check retainer and ball assembly for damage. Inspect housing for warpage.

Remove seal from 2nd clutch piston. Lubricate NEW seal with ATF and install.

Remove retainer and ball assembly from housing using a 3/8" drift. Tap in NEW retainer and ball assembly using drift.

Assemble piston into housing. Install apply ring and return spring. Install snap ring and wave plate. Assemble clutch plates; start with composition plate, and then alternate between steel and composition plates. Install backing plate with smooth side down. Install snap ring. Apply 20-psi (1.4 kg/cm 2 ) air pressure to passage marked "2" to check clutch operation.

Scheme 46

Compress return spring using a press, and remove snap ring. Remove retainer and 4th clutch piston from sprocket support.

Inspect driven sprocket support for worn or damaged oil seal rings. Check bushing and piston seal surface for damage. Check for blocked or interconnected oil passages and cup plug. Check chain scavenging scoop and baffle for cracks. Inspect piston, seals and thrust washer for damage. Check spring retainer for distorted springs. Inspect driven sprocket bearing for damage.

Inspect output shaft snap ring groove, splines, journal and bearings for damage. Replace if necessary.

Inspect drive and driven sprockets for damaged or chipped teeth. Pull drive link chain toward transaxle case. Measure distance between drive link chain and transaxle case. Replace drive link chain if measurement is less than 1/8". Check sprockets for damaged bearing surfaces or splines. Check thrust washers and drive link for excessive wear or damage. Inspect 4th clutch shaft and turbine shaft for damaged bushings, splines or seals. Replace if necessary.

Thoroughly clean and air dry control valve assembly. Remove each valve train, beginning with upper left hand corner. Cover bores when removing roll pins, because some valves are under spring pressure. Remove blind hole roll pins with a modified drill bit. Lay valves, springs and bushings on a clean surface in the order removed. (Scheme 47)

Clean valves, springs and bushings in solvent. DO NOT use shop rags to clean control valve assembly components. Inspect valves and bushings for scoring, nicks and scratches. Inspect springs for damaged or distorted coils. Inspect control valve assembly casting for porosity, interconnected oil passages and damaged machined surfaces.

To reassemble control valve assembly components, reverse disassemble procedure. Ensure all components are installed in original locations.

Scheme 47

Clean and air dry oil pump. Remove oil pump cover bolts. Remove vane rings, vanes and rotor. Remove seal and springs. Remove slide, slide seal support and slide seal. Remove pivot pin. (Scheme 48)

1. Inspect pump body for porosity, interconnected oil passages, or damaged inner pump area surface or machine facing. Check slide, springs, rotor and vanes for damage. Inspect slide seal, slide support and seals for damage. (Scheme 48)
2. Measure undamaged area of rotor, vane or slide to check for proper size. See OIL PUMP COMPONENT THICKNESS table. (Scheme 49) En sure replacement parts are matched to fit within specification.

Note. Oil pump components are matched sets. DO NOT mix old and new parts.

OIL PUMP COMPONENT THICKNESS

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. Press both springs into pump body. Install "O" ring and seal ring onto slide. (Scheme 48) 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. Install pump pressure screen into pump (screen has one-way tab).

Scheme 48

Scheme 49

Thermo Element Replacement

If thermo element replacement is necessary, remove retainers, pins and thermo element. Remove plate element. For NEW element, set thermo pin height with Height Gauge (J-34094-A). (Scheme 50) Install element plate. Install pin and retainer assemblies, and set height with height gauge. Install NEW thermo element.

Scheme 50

Inspect servo pistons and seals for damage or cracks. DO NOT remove seals unless replacement is required. Inspect springs for damaged coils.

DO NOT interchange servo parts. Assemble spring retainer onto pin. Forward servo spring retainer step must face spring. Reverse servo cushion spring must be installed between 2 spring retainers. Install cushion spring, servo piston and snap ring onto pin. (Scheme 27)

TRANSAXLE REASSEMBLY

Note. All selective snap ring and thrust washer measurements taken during disassembly must be rechecked at appropriate reassembly stage.

1. Install and ensure sun gear shaft, forward band, 1-2 band, reaction sun gear and reverse reaction drum are in place. Ensure 1-2 band anchor pins engage band, and 1-2 band assembly stop is in place.
2. Recheck final drive end play. See «FINAL DRIVE CARRIER ASSEMBLY»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) under COMPONENT DISASSEMBLY & REASSEMBLY. Install thrust washer onto input shaft and hold in position with petroleum jelly. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates.
3. 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.
4. Check input clutch housing end play. See «INPUT & 2ND CLUTCH ASSEMBLIES»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e__input-2nd-clutch-assemblies) under TRANSAXLE DISASSEMBLY. (Scheme 38) Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be.0-.006" (.0-.152 mm). If clearance is not as specified, use different thrust washer. See «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(/oldsmobile/achieva/i-final-1998-1998/remont/automatic-trans/#automatic-transaxle-overhaul-testing-4t60-e) table.
5. Install reverse reaction plate and thrust washer. Install thrust bearing with large race facing down. Install 2nd clutch assembly onto input clutch assembly. Clutch plates must engage input clutch hub, and clutch housing must engage reverse reaction drum splines.
6. Install reverse band into case, locating band on anchor pins. Install thrust washer to driven sprocket support, and hold washer in position with petroleum jelly. Install driven sprocket support into case, ensuring support lube hole aligns with hole in bottom of case. Install output shaft into case. Install "C" ring onto output shaft through bottom of case. Push "C" ring onto output shaft.
7. Coat seal installer with petroleum jelly, and place seal installer over turbine shaft. Slide oil ring seals into position. Using appropriate seal sizer, size seals by gently twisting sizer over seal.
8. Install thrust washer onto drive sprocket, and hold washer in position with petroleum jelly. Install sprockets and drive link chain onto case. Ensure Bronze colored link faces direction of removal. If NEW drive link chain is installed, link direction must be up. Install chain scavenging scoop.
9. Install thrust washer onto driven sprocket and retain with petroleum jelly. Insert 4th clutch hub and shaft through driven sprocket, and install clutch apply plate with machined side facing down. (Scheme 36) Install 4th clutch plates starting with steel plate.
10. If necessary, pry out axle seal, and tap NEW seal into place. Install 3-4 accumulator components into channel plate. Install 3-4 accumulator cup. Install channel plate gaskets. Install thrust washer onto channel plate. (Scheme 34)
11. Install channel plate onto case. Channel plate lugs must align with tangs on 4th clutch plates and apply plate. (Scheme 36) Install and tighten channel plate bolts. (Scheme 35) Install manual valve link, retainer spring and manual valve. Install oil dam and channel plate gaskets. Install 4 check balls in channel plate, using petroleum jelly to retain check balls. (Scheme 33) Install TCC solenoid screen.
12. Install NEW spacer plate-to-channel plate gasket onto channel plate using alignment pins. Install spacer plate onto gasket. Install NEW spacer plate-to-valve body gasket onto spacer plate. (Scheme 51)
13. Install oil pump drive shaft. Install shift solenoid screens. Install 6 check balls into control valve assembly. Use petroleum jelly to retain check balls in place. (Scheme 51)
14. Install control valve assembly onto channel plate using alignment pins. (Scheme 51) Install and tighten control valve assembly bolts. (Scheme 30) Install oil pump onto control valve assembly. Install and tighten oil pump bolts. (Scheme 31)
15. Install wiring harness to harness clips. Connect wiring harness connectors to solenoids and temperature sensor. Install temperature sensor into channel plate and attach to clip. (Scheme 29) Ensure connectors for solenoid "B" and TCC solenoid are connected correctly. To identify correct wire for TCC solenoid, look for diode in wiring harness under shrink wrap. If solenoid "B" and TCC solenoid wires are reversed, transaxle will shift into Reverse okay, but engine will stall immediately after transaxle is shifted into Drive.
16. Install gaskets and seal onto case side cover and channel plate. Install case side cover. Install accumulator pins into case. Install accumulator springs and pistons into accumulator housing. Springs and pistons are transaxle model specific. Install accumulator spacer plate and gaskets. Install accumulator housing onto accumulator cover. Install and tighten accumulator housing bolts.
17. Install lube oil hose onto lube oil pipe. Install hose clamps. Install lube pipe retainer clip onto pipe and washer assembly. Install pipe and washer assembly onto lube oil hose.
18. Install servo pipes into accumulator cover and 2-1 manual servo cover. Ensure lube oil pipe and manual servo pipe are installed correctly. Manual servo pipe should be installed in accumulator housing center hole, and lube oil pipe should be installed in right side hole. (Scheme 28) Forward servo pipe cannot be installed in wrong hole due to a larger pipe diameter.
19. If pipes are installed incorrectly, lube oil will apply 2-1 manual servo and band as soon as engine is started. Vehicle will display a tie-up condition in Park and Reverse, and on a 2-3 upshift. Vehicle will move forward in Neutral if condition exists.
20. Install 2-1 manual servo components into transaxle case. Install accumulator cover, pipes and retainer onto case as an assembly. (Scheme 28) Install pipe and washer assembly into transaxle case. Ensure pipe and washer assembly is installed into final drive internal gear. Lock retainer into case. Tighten hose clamps.
21. Install NEW oil filter seal, filter and gasket into case. Install oil pan. 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. Install forward and reverse servo covers into case. Install snap ring and cover bolts. (Scheme 28)
22. Install speed sensor. Install modulator valve into case. Install NEW "O" ring seal onto modulator. Install modulator into case. Install retainer and bolt. Hold torque converter in place for installation.

INPUT CLUTCH THRUST WASHER IDENTIFICATION

Scheme 51

TRANSAXLE SPECIFICATIONS

TRANSAXLE SPECIFICATIONS

Note. Use Figs. (Scheme 52) - (Scheme 54) for disassembly and reassembly reference.

Scheme 52

Scheme 53

Scheme 54

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

WIRING DIAGRAMS

Note. See AUTO TRANS DIAGNOSIS 4T60-E article.

See also:
• AUTO TRANS DIAGNOSIS 4T60-E
• CLUTCH & BAND APPLICATION
• ROAD TEST
• HYDRAULIC PRESSURE TESTS
• TROUBLE SHOOTING
• TORQUE SPECIFICATIONS
• INPUT & 2ND CLUTCH ASSEMBLIES