Automatic Transaxle Overhaul & Testing - 4T60-E: Overhaul Oldsmobile Eighty-Eight X

TRANSAXLE DISASSEMBLY

Note. (Scheme 43)- (Scheme 46) for disassembly and reassembly reference.

Note. Beginning on February 2, 1995, (about half way through 1995 model year) all 4T60-E transaxles were built using a redesigned 2-1 servo square cut seal. Seal is located above 2-1 servo cover. see scheme 6 Seal requires a deeper seal pocket in transaxle case. This design change improves assembly process. NEW design seal (.132") is twice as tall as previous design seal (.066"). Seal thickness and outside diameter did not change. Seal retains fluid in forward servo circuit to apply forward band. Seal pocket in transaxle case is machined deeper (.112") then previous design (.054"). Redesigned seal is available from manufacturer in Service Package (24204817). Both seal designs are included in this package. Seals are NOT interchangeable.

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 25) Remove forward servo cover bolts. Remove servo cover and forward servo assembly from case. (Scheme 26)

Scheme 25

Scheme 26

CHANNEL PLATE ASSEMBLY & 4TH CLUTCH

1. Remove oil dam from cavity above 4th clutch assembly. Disconnect manual valve link from manual valve, and pull spring back. Place detent lever in Park position for clip removal. Remove channel plate attaching bolts. Remove channel plate and channel plate gaskets.
2. Remove input clutch accumulator piston assembly and converter clutch accumulator piston assembly. Remove 4th clutch plates and apply plate. Remove 4th clutch hub thrust washer. Remove 4th clutch hub and shaft. (Scheme 46)

FINAL DRIVE 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.
2. Check final drive end play. See «FINAL DRIVE ASSEMBLY»(ref-25523-S26383191322001011700000) under COMPONENT DISASSEMBLY & REASSEMBLY. (Scheme 30) Remove final drive assembly and selective thrust washer and bearing. Remove final drive internal gear snap ring and internal gear from case.

DRIVE LINK ASSEMBLY

Note. (Scheme 43)for exploded view of all internal components (from drive link support to final drive assembly). (Scheme 44)for thrust washer and bearing locations. (Scheme 45)for lip seal locations.

1. Remove "O" ring from turbine shaft. (Scheme 46) Remove turbine shaft drive sprocket, driven sprocket and drive link chain together as an assembly. Note position of Copper-colored link on drive link chain; it should be installed 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.

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 27) 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 28)
3. Install differential thrust washer, thrust bearing and rear extension housing. 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 28)
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»(ref-25523-S42525255002001011700000) under TRANSAXLE REASSEMBLY.

Scheme 27

Scheme 28

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 output shaft. Remove forward band. DO NOT clean bands in solvent.

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 assembly into case.
6. To measure final drive end play, install dial indicator so pointer contacts Adapter (J-26958-10). (Scheme 30) Lift speed sensor rotor with Snap Ring Remover (J-28585), and read dial indicator.
7. Correct end play is.008-.025" (.20-.63 mm). If necessary, adjust end play with selective carrier-to-case thrust washer. See «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(ref-25523-S24193237872001011700000).

CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES

Scheme 29

Scheme 30

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.

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

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 31) Remove input sprag assembly from outer race. Note sprag cage direction for installation reference. Remove end bearing from outer race.

Scheme 31

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 31)
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 will lock. Install 3rd sprag and input sprag assemblies onto input sun gear. Ensure input sprag and 3rd sprag assemblies rotate in correct direction. (Scheme 32)

Scheme 32

INPUT CLUTCH & 3RD CLUTCH ASSEMBLY

Note. Input clutch plates have been revised. Original design components are not available as replacement parts and cannot be mixed with NEW design components. See INPUT CLUTCH PLATE UPDATE .

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. see scheme 17 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.

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. see scheme 17 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 stepped side facing up. Install snap ring.
4. Assemble input clutch plates; start with composition plate, and then alternate between steel and composition 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 ).

Remove snap ring and backing plate. (Scheme 33) Remove clutch plates, waved plate and snap ring. Remove apply ring and spring return assembly. Remove apply piston.

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

Scheme 33

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

Thoroughly clean and air dry valve body. 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 34)

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

Scheme 34

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.

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. see scheme 9 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 35

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 25)and (Scheme 26).

TRANSAXLE REASSEMBLY

Note. (Scheme 43)- (Scheme 46) for disassembly and reassembly reference.

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

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

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 ASSEMBLY»(ref-25523-S26383191322001011700000) 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»(ref-25523-S18179450362001011700000) under TRANSAXLE DISASSEMBLY. (Scheme 28) Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be.000-.006" (.000-.152 mm). If clearance is not as specified, use different thrust washer. See «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(ref-25523-S42525255002001011700000). INPUT CLUTCH THRUST WASHER IDENTIFICATION Washer ID No. Color Thickness: In. (mm) 1 Orange/Green.114-.118 (2.90-3.00) 2 Orange/Black.120-.124 (3.05-3.15) 3 Orange.126-.130 (3.20-3.30) 4 White.132-.136 (3.35-3.45) 5 Blue.138-.142 (3.50-3.60) 6 Pink.144-.148 (3.65-3.75) 7 Brown.150-.154 (3.80-3.90) 8 Green.156-.159 (3.95-4.05) 9 Black.161-.165 (4.10-4.20) 10 Purple.167-.171 (4.25-4.35) 11 Purple/White.173-.177 (4.40-4.50) 12 Purple/Blue.179-.183 (4.55-4.65) 13 Purple/Pink.185-.189 (4.70-4.80) 14 Purple/Brown.191-.195 (4.85-4.95) 15 Purple/Green.197-.201 (5.00-5.10)
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 (J-29569-1 and J-29829-1) with petroleum jelly, and place seal installer over turbine shaft. Slide oil ring seals into position. Using Seal Sizer (J-29569-2 and J-29829-1), 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 colored link faces upward.
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 identification mark 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 pistons and pins into channel plate. Install springs into case. Install channel plate gaskets and modulator port gasket. Install thrust washer onto channel plate.
11. Install channel plate onto case. Channel plate lugs must align with tangs on 4th clutch plates and apply plate. (Scheme 36) Install sleeve into channel plate. Install oil reservoir baffle, detent spring and roller. Install channel plate gaskets.
12. Install and tighten channel plate bolts. (Scheme 37) Install 4 check balls in channel plate, using petroleum jelly to retain check balls. (Scheme 38) Install converter clutch screen. Install detent spring and roller assembly.
13. Install NEW spacer plate/channel plate gasket onto channel plate using alignment pins. Install spacer plate onto gasket. Install NEW spacer plate/valve body gasket onto spacer plate. (Scheme 39)
14. Install oil pump drive shaft and converter clutch solenoid screen. Install 6 check balls into valve body assembly; use petroleum jelly to retain check balls in place. (Scheme 40)
15. Install valve body assembly onto channel plate using alignment pins. (Scheme 41) Install servo pipes into valve body using retainer and bolt. Install pump onto valve body assembly. Install pump attaching bolts. (Scheme 42)
16. Install gaskets onto case and channel plate. Install side cover. Install accumulator pins into case. Install accumulator springs into case. Larger springs are for 3-4 accumulator.
17. Install lube oil pipe retainer spring into pocket. Install lube oil pipe retainer onto lube oil pipe and "O" ring onto retainer. Install lube oil pipe into case. Ensure pipe is installed into driven sprocket support lube hole.
18. Install spacer plate and NEW gaskets onto case. install oil scavenger scoop. Install wiring to solenoids. Ensure wire connectors for solenoid "B" and TCC solenoid are connected correctly. To identify wire colors 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.
19. Install accumulator cover, pipes and retainer onto case as an assembly. Ensure lube oil pipe and 2-1 manual servo pipe are installed correctly. The 2-1 manual servo pipe should be installed in accumulator housing center hole, and lube oil pipe should be installed in right side hole. see scheme 6 Forward servo pipe cannot be installed in wrong hole due to a larger pipe diameter.
20. 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 exist.
21. Ensure lube oil pipe is installed into final drive internal gear. Install NEW filter lip seal, filter and gasket into case. Install 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.
22. Install speed sensor. Install modulator valve into case. Install NEW "O" ring seal onto modulator. Install modulator into case. Install retainer and bolt. Use Converter Holding Strap (J-21366) to hold torque converter in place for installation.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47