Automatic Transaxle Overhaul & Testing - 4T65-E: Diagnosis Pontiac Aztek I

TROUBLE SHOOTING

Note. Transaxle malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of hydraulic, mechanical or electronic components. Ensure all concerns have been properly checked prior to transaxle overhaul. See appropriate DIAGNOSIS article.

Visual Inspection

Inspect and replace torque converter for the following conditions

1. Overheated (torque converter will be blue in color).
2. ATF leaking at weld areas.
3. Damaged torque converter pilot.
4. Evidence of metal particles in torque converter, oil cooler, or cooler pipes.
5. Damaged torque converter stator, damaged pump, or damaged turbine.
6. Damaged or worn torque converter bushing.
7. Contaminated ATF due to engine coolant.

Inspect torque converter for stripped bolt hole threads. Repair as necessary.

Inspection

1. Inspect components still on transaxle case for the following: Loose, cross-threaded, or damaged ATF cooler pipe fittings. Loose, missing, or damaged transaxle name plate. Loose, plugged, or damaged vent assembly. Loose, cross-threaded, or damaged oil pressure test hole plug.
2. Inspect transaxle case for the following: Damaged or porous gasket sealing surfaces. Stripped or damaged bolt or screw holes (repair with thread insert). Damaged or porous case oil passages. Damaged snap ring grooves or housing splines. Loose, missing, or damaged band anchor pins. Damaged or porous case surfaces. Plugged drain back holes for torque converter oil seal.

Inspect drive sprocket support for the following

1. Damaged splines.
2. Damaged drive sprocket support bearing.
3. Damaged turbine shaft bushing (pressed inside support).

Remove drive sprocket support bearing and/or drive sprocket support assembly only if damaged.

Inspection & Reassembly

1. Inspect park system components for the following: Worn park pawl actuator guide. Damaged or bent park pawl actuator assembly. Damaged manual shift shaft detent lever or IMS detent lever. Worn, stripped, or bent manual shift shaft. Bent or damaged manual valve link. Kinked or bent manual valve link spring. Replace components as necessary. (Scheme 12)
2. Install NEW shift shaft seal into case using 9/16" socket and hammer. (Scheme 13) Install NEW parking pawl actuator guide "O" ring seal onto parking pawl actuator guide. Install actuator guide into case. Align slot for actuator guide pin in parking pawl with pin hole in case. Install actuator guide pin using mallet. see scheme 89
3. Install manual shift shaft detent lever onto manual shift shaft. Install nut on shift shaft and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000). Install detent lever onto parking pawl actuator. Install manual shift shaft detent lever assembly and parking pawl actuator assembly into case. (Scheme 14)
4. Align groove for manual shift shaft pin with pin hole in case. Install manual shift shaft pin using mallet. (Scheme 15)

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Inspect differential carrier internal gear assembly for the following

1. Damaged or worn bushings.
2. Plugged lube oil holes.
3. Damaged case splines.
4. Damaged or worn gear teeth.
5. Damaged or worn park pawl assembly.
6. Damaged snap ring.

Replace components as necessary. (Scheme 16)

Scheme 16

1. Inspect differential carrier assembly for the following: Damaged or worn teeth, bearing rollers, washers, or pins on differential planetary pinion gear. Damaged or worn teeth or splines on final drive sun gear. Damaged or worn teeth, splines, or thrust washers on differential side gear. Damaged or worn teeth, thrust washers, or shaft on differential pinion gear. Damaged or worn lugs or splines on parking gear. Damaged VSS reluctor wheel. Damaged internal gear/parking gear thrust bearing, differential carrier/sun gear thrust bearing or differential carrier/case thrust bearing. Damaged or worn differential carrier/case selective thrust washer. Damaged differential/final drive carrier housing. Replace components as necessary. see scheme 56, see scheme 101, see scheme 103 and see scheme 104. If VSS reluctor wheel is damaged, see «VEHICLE SPEED SENSOR RELUCTOR WHEEL»(ref-131089-S02933501672001121000000).
2. Inspect final drive sun gear shaft for the following: Damaged or worn splines. Cracks at lube oil holes. Damaged or worn bearing journals.

Inspect case extension for the following

1. Damaged or porous sealing surface for case extension seal.
2. Damaged or porous sealing surface for VSS.
3. Damaged or porous sealing surface for right drive shaft oil seal.
4. Damaged bolt holes.
5. Worn or damaged front differential carrier bushing or output shaft bearing assembly.
6. Porous or damaged case extension housing.

Repair as necessary. (Scheme 17)

Scheme 17

1. Inspect forward band assembly for the following: Damaged or severely worn friction material. Damaged apply or anchor pin features.
2. Inspect differential carrier internal gear thrust washer for damage. Replace components as necessary. see scheme 85

Inspect 1-2 support roller clutch components for the following

1. Scored or burned contact surface for manual 2-1 band on 1-2 support drum.
2. Damaged or worn forward drum bushing.
3. Damaged or worn inner race of 1-2 support roller clutch.
4. Damaged or worn 1-2 clutch roller assembly.
5. Damaged thrust bearing.

Replace components as necessary. see scheme 109

Inspect 2-1 manual band for cracked, separated or worn friction material. Inspect for cracks around apply lugs. Replace components as necessary. see scheme 83

Inspect reaction sun gear and drum for the following

1. Worn or scored bushings.
2. Damaged reaction sun gear teeth.
3. Band apply area of drum for discoloration or wear.
4. Welds connecting sun gear to drum for voids or cracks.
5. Worn or damaged 1-2 support outer race.

Replace components as necessary. (Scheme 18)

Scheme 18

1. Using feeler gauge, check for excessive pinion gear end play in input carrier and reaction carrier assemblies. End play should be.009-.030" (.23-.76 mm). If end play is not as specified, replace appropriate component. (Scheme 19)
2. Inspect thrust bearings, reaction carrier and input carrier for the following: Damaged cage. Damaged or missing rollers. Damage to pinion teeth. Damage to internal gear teeth. Damage to spline teeth. Replace components as necessary. (Scheme 20)

Scheme 19

Scheme 20

1. Inspect for damaged 2nd clutch and reverse reaction drum splines. Original 2nd clutch and reverse reaction drums have splines with 25-degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10-degree sides.
2. Inspect reverse reaction drum for cracks, damaged splines or distortion. see scheme 75 Replace drum if necessary.

Inspect outer races for worn or damaged splines, scoring on inside diameter of races, wear or cracks. Inspect sprag components for flat spots. Inspect cage assemblies for distortion or broken ribbon tabs. Inspect end bearings and center bearing for cracks. Check input sun gear spacer for worn or damaged splines, or wear and cracks. Inspect input sun gear for worn or damaged splines or plugged lube holes or cracks. see scheme 116and see scheme 117. Replace components as necessary.

1. Inspect input clutch housing for the following: Plugged feed passages. Worn or damaged splines. Input shaft bushing wear. Seal ring groove nicks or burrs. Crack or blocked fluid passages in input shaft. Damage or wear to thrust bearing in input clutch housing. Replace components as necessary. see scheme 128
2. With check ball in seated position, add ATF to input clutch housing, and inspect for leaks. If check ball assembly leaks, see «INPUT CLUTCH HOUSING CHECK BALL VALVE»(ref-131089-S21694241182001121000000). Inspect input clutch piston for cracks or damage to seal grooves. Inspect for wear on piston lugs. Inspect input clutch and 3rd clutch spring assemblies for damaged cage or distorted or missing springs. DO NOT attempt to reuse 3rd clutch piston and seal. see scheme 124and see scheme 126. Check input shaft thrust bearing for damage or wear. see scheme 122 Replace components as necessary.

1. Inspect 2nd clutch housing for the following: Leaking or damaged ball check valve. Turn housing to seat check ball. Using ATF, check for leaking or damaged check ball valve in 2nd clutch housing. If check ball assembly leaks, replace check ball assembly. See «2ND CLUTCH HOUSING CHECK BALL VALVE»(ref-131089-S07668706412001121000000). Scored or worn bushings. Discolored band surface or wear on drum caused by excess heat. Flatness of band surface on drum. Damaged reverse reaction drum splines. Cracks in welds. Replace components as necessary. see scheme 139
2. Check for damaged reverse reaction drum splines. see scheme 75 Original 2nd clutch and reverse reaction drums have splines with 25-degree sides and have tendency to strip. New design 2nd clutch and reverse reaction drum kit (GM P/N 24213402) have splines with 10-degree sides. Check for cracks in welds. Inspect backing plate and waved plate for cracks and heat spots. Inspect steel and composition plates for wear, lining separation, pitting, flaking or damage. see scheme 136
3. Inspect apply ring and spring assembly for damage. Inspect piston and piston seals for damage. Inspect 2nd clutch housing for damaged inner piston seal. see scheme 138

Inspect reverse band for cracks, scoring, lining separation or wear on fiber material. Inspect apply lug for cracks. Replace components as necessary. see scheme 74

1. Inspect driven sprocket support components for the following: Worn or cut oil seal rings. Rolled or cut second clutch housing oil seal ring seals. Damage to piston seal surface in driven sprocket support. Blocked or porous oil passages in driven sprocket support. A leaking or missing cup plug. Damaged 4th clutch piston. Cracked or distorted 2nd clutch housing thrust washer. Distorted or missing springs in 4th clutch spring assembly. Driven sprocket bearing assembly for foreign material and missing, flat or damaged rollers.
2. Replace Teflon oil seal rings if cut or damaged, or if complete overhaul is being performed. Check all seal ring grooves for debris, burrs or damage. see scheme 144

1. Inspect driven sprocket and drive sprocket for the following: Worn or chipped teeth. Uniform teeth size. Stripped or damaged splines. Bearing surface damage. Replace components as necessary. see scheme 152and see scheme 153.
2. Inspect 4th clutch shaft, driven sprocket and drive sprocket thrust washers for wear or cracks.
3. Inspect turbine shaft for a cracked sleeve, damaged bushing journals or stripped or damaged splines. Replace components as necessary.

Inspect drive chain assembly for cracks, binding links or damage. Check input speed sensor reluctor wheel for damaged teeth, worn or damaged thrust surface and damaged or missing locating pins. Replace components as necessary. see scheme 158

1. Inspect 4th clutch for the following conditions: Wear or damage to steel plates. Peened splines, flaking, or worn composition plates.
2. Inspect 4th clutch shaft for the following: Cut or worn 4th clutch plate splines. Stripped input sun gear splines. Damaged bushing journal. Cracks or damage to hub or shaft.

Replace components as necessary. see scheme 68

Note. For 4th clutch component reassembly, see TRANSAXLE REASSEMBLY .

1. Inspect 3-4 accumulator piston cylinder for porosity, scored pin or nicked or grooved piston sleeve. Inspect piston pin for scoring and free movement in piston bore. Inspect springs for distorted or broken coils. Inspect piston cylinder for porosity or cracks. Inspect for rough or scored seal surface, or cut seal. Inspect check ball, spring and bore plug. see scheme 159
2. DO NOT remove blow-off check balls unless damaged. Inspect manual valve, link and spring link for damage. Check manual valve for binding or looseness in case cover. Check case cover plugs and orifice cup plug. Replace plugs if loose, plugged or missing.
3. Inspect shaft bearing for damage. DO NOT remove bearing unless bearing is damaged. Inspect oil seal for missing garter spring or for cut lip seal.
4. Inspect case cover for porosity, interconnected fluid passages, cracks or rough machined surfaces.
5. Inspect input speed sensor for damaged or missing magnet, damaged housing, bent or missing electrical terminals, or damaged speed sensor clip.

Inspect output shaft for damaged bushing journals, stripped splines or retaining ring groove damage. see scheme 17

Check for damaged connector, cracked housing, signs of rotor damage or cuts or nicks on seal. see scheme 16

1. Inspect control valve body for worn or damaged oil pump drive shaft bearing journal (not serviceable separately from control valve body), damaged or porous casting, damaged sealing surfaces and debris in fluid passages.
2. Before disassembly, inspect control valve body components using small pick or screwdriver for valves binding or sticking in bores or bushings, broken, missing or damaged springs, missing or damaged retainers, damaged solenoid valves or debris in valve line-ups or solenoid valves.
3. During disassembly, inspect control valve body for worn or damaged valves, valve bores or bushings, broken, missing or damaged springs, missing or damaged retainers, damaged solenoid valves, debris in valve line-ups or solenoid valves.
4. Inspect Transmission Fluid Pressure (TFP) manual valve position switch assembly for damaged electrical connector terminals, damaged seals, damaged switch membranes or debris on switch membranes. see scheme 47

1. Inspect control valve body spacer plate for plugged holes, damaged sealing surfaces, or plugged or damaged screen/seal assemblies. Inspect each check ball seat on spacer plate for excessive peening. Place check ball on each seat. Using flashlight, look for visible light between check ball and seat. (Scheme 21) If light is visible between check ball and seat, replace spacer plate. For check ball locations see scheme 53and see scheme 54.

Scheme 21

1. Inspect oil pump for the following: Worn, scored or gouged pump slide. Cracks, wear or damage to rotor or vanes. Cuts or damage to seals. Broken priming springs. Damaged oil pump drive shaft bearing (bearing is not serviced separately from rotor). (Scheme 22)
2. Inspect oil pump body for the following: Porosity Worn, scored or damaged pump pocket. Interconnected oil passages. Damaged machined surfaces.
3. Inspect pump outlet screen for damage or debris. Inspect oil pump cover for cracks, wear or gouges from pump vanes.
4. Measure pump rotor, oil pump vanes and oil pump slide. (Scheme 23) Select proper replacement size. See «OIL PUMP COMPONENT SPECIFICATIONS»(ref-131089-S32123998872001121000000) table.
5. Install outlet screen into oil pump body. Install slide seal support and slide seal into slot on pump slide. Install pump slide and slide pivot pin into pump body.
6. Install outer and inner priming springs into pump body. Install 1st vane ring into pump body. Insert pump slide "O" ring seal and slide oil seal ring into pump slide. (Scheme 22)
7. Insert rotor into pump body. Install pump vanes into rotor. Pump vanes must be flush with top of rotor. Install 2nd vane ring onto rotor. Install pump cover and bolt. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-131089-S30575035922001121000000).

OIL PUMP COMPONENT SPECIFICATIONS

Scheme 22

Scheme 23

Inspect wiring harness for cut or pinched wires, cut wire insulation, bent or broken electrical connectors or damaged terminals. (Scheme 24)

Scheme 24

Inspect case side cover for damaged or porous gasket sealing surfaces, and damaged or stripped bolt holes. Inspect case side cover gasket and channel plate seal for damage. (Scheme 25)

Scheme 25

Inspect 2-1 manual band servo components for the following

1. Damaged, worn or porous servo piston cylinder.
2. Damaged, worn or porous servo piston.
3. Damaged or worn servo piston pin.
4. Broken or damaged servo piston spring.
5. Broken or damaged servo piston cushion spring.
6. Damaged or plugged servo exhaust screen.
7. Damaged servo cover seal.
8. Damaged servo piston seal.
9. Damaged servo piston cylinder "O" ring seal.

1. Inspect accumulator housing, accumulator cover spacer plate and accumulator cover for the following: Damaged oil pipe holes in accumulator cover. Damaged, improperly machined or porous accumulator cover. Bent or damaged accumulator cover spacer plate. Stripped or damaged bolt holes in accumulator housing. Damaged, worn, improperly machined or porous accumulator housing. Leaking, loose or missing cup plugs in accumulator housing.
2. Inspect accumulator pistons, springs, seals and pins for the following: Broken or collapsed piston outer springs. Broken or collapsed piston cushion springs. Bent or worn accumulator piston pins. Damaged, worn or porous accumulator pistons. Damaged accumulator piston seals.
3. Inspect servo and lube oil pipe components and 2-1 manual band servo cover for the following: Damaged lube, and servo oil pipe holes in servo cover. Damaged, improperly machined or porous servo cover. Bent, plugged or damaged lube and servo oil pipes. Plugged or damaged lube oil hose. Damaged hose clamps and/or lube oil pipe retainer. Missing lube oil pipe washer.

1. Inspect for damaged sealing surface. Inspect for dented or cracked bottom pan surface. Inspect oil pan gasket for bent or damaged seal core, damaged rubber seal surface or damaged gasket. Check oil pan magnet for damage or misalignment. Clean oil pan, gasket and magnet. see scheme 16

Inspect forward band servo components for the following

1. Damaged, worn or porous servo piston.
2. Damaged servo piston oil seal ring.
3. Damaged, worn or porous servo cover.
4. Damaged servo cover seal.
5. Broken or collapsed servo piston return spring.
6. Broken or collapsed servo piston cushion inner spring.
7. Broken or collapsed servo piston cushion outer spring.
8. Damaged or worn servo piston apply pin.

see scheme 175

Inspect reverse band servo components for the following

1. Damaged, worn or porous servo piston.
2. Damaged servo piston oil seal ring.
3. Damaged, worn or porous servo cover.
4. Damaged servo cover "O" ring seal.
5. Damaged servo cover retaining ring.
6. Broken or collapsed servo piston return spring.
7. Broken or collapsed servo piston cushion springs.
8. Damaged or worn servo piston apply pin.

see scheme 176