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

GEAR RATIOS

TRANSAXLE GEAR RATIOS

Stator Check

With torque converter removed from vehicle, stator roller clutch can be checked by inserting 2 fingers into splined inner race of roller clutch and attempting to rotate race in both directions. Inner race should rotate freely clockwise, but should not rotate or should be difficult to rotate counterclockwise.

End Play Check

Mount Torque Converter End Play Fixture (J-35138) and Dial Indicator (J-8001) on torque converter to check end play. End play should be 0-.020" (0-.50 mm). (Scheme 115)

Scheme 115

REVERSE BAND SERVO

1. Using long screwdriver, depress reverse band servo cover by prying against holding fixture. Pry retaining ring from reverse band servo cover. (Scheme 116)
2. Remove screwdriver. Servo assembly will push servo cover up. Using small screwdriver, pull servo cover "O" ring seal out through slot in case. Cut servo "O" ring seal. Depress reverse band servo cover. Grasp one end of cut seal and pull from servo cover. Servo assembly will push servo cover up. Remove servo cover, reverse band servo assembly and reverse band servo piston return spring. (Scheme 117)

Scheme 116

Scheme 117

FORWARD BAND SERVO

Position transaxle with oil pan facing up. Using long screwdriver, depress forward band servo assembly cover by prying against work bench. Hold servo assembly and remove forward band servo cover bolts. (Scheme 118) Remove screwdriver. Servo assembly will push servo cover out. If cover does not move, tap cover with mallet. Remove servo cover and cover seal. Remove servo assembly. Remove piston return spring from forward band servo. (Scheme 119)

Scheme 118

Scheme 119

OIL PAN & FILTER

Remove oil pan bolts. Remove oil pan and gasket. Using screwdriver, pry oil filter out of case. Pry oil filter seal out of case. DO NOT damage case sealing surface. see scheme 16 Inspect oil pan magnet for steel particles. Excessive amounts of steel shavings indicates internal transaxle damage. Using screwdriver, pry metal crimping away from top of oil filter and pull oil filter apart. Inspect oil filter for clutch plate friction material, steel particles and Bronze slivers, indicating bushing damage or internal transaxle damage.

CONTROL VALVE BODY, OIL PUMP & VEHICLE SPEED SENSOR

1. Position transaxle with control valve body cover facing up. Remove case side cover (control valve body cover) bolts. (Scheme 120) Remove cover and gaskets. see scheme 15 Using small screwdriver, pry wiring harness electrical connectors off transaxle fluid pressure manual valve position switch, 1-2 and 3-4 shift solenoid, 2-3 shift solenoid, TCC PWM solenoid, pressure control solenoid and input speed sensor. Gently pull transaxle fluid temperature sensor from clip. (Scheme 121)and (Scheme 122).
2. Lift wiring harness assembly off transaxle. Remove oil pump assembly bolts. DO NOT remove No. 1 oil pump cover bolt at this time. (Scheme 123) Remove wiring harness clip. Lift oil pump assembly off control valve body. (Scheme 124) Set oil pump assembly on its cover.
3. Remove control valve body bolts. (Scheme 125) Manual valve position switch is very delicate, use care when handling. Carefully lift manual valve position switch off control valve body. (Scheme 126) Remove control valve body. (Scheme 127) Remove 4 check balls from case cover. (Scheme 128) Remove 2 bolts retaining spacer plate and gaskets to valve body. Remove spacer plate with 2 screen/seal assemblies and gaskets from valve body. Remove 6 check balls from valve body. (Scheme 129) Remove case cover pin.
4. Remove oil pump drive shaft from case cover. (Scheme 130) Position transaxle so Vehicle Speed Sensor (VSS) is facing up. Remove VSS bolt and VSS. see scheme 16

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

OUTPUT SHAFT

1. Remove case extension bolts. Remove case extension and extension seal. (Scheme 131) Leave front differential carrier thrust washer and bearing on carrier. Rotate differential carrier until differential carrier pinion shaft is in horizontal position.
2. Place Axle Remover Wedge (J 42562) between end of output shaft and differential pinion shaft. Using hammer, strike axle removal wedge to compress snap ring and push output shaft from differential side gear. (Scheme 132) Remove differential carrier assembly and snap ring from output shaft. (Scheme 133) Remove output shaft assembly. (Scheme 134)

Scheme 131

Scheme 132

Scheme 133

Scheme 134

FRONT DIFFERENTIAL CARRIER END PLAY CHECK

1. Ensure thrust washer and bearing are on front differential carrier. Install case extension seal onto case extension, if removed. Install case extension onto transaxle. (Scheme 131) Install 2 case extension bolts. DO NOT tighten bolts to specification. Only tighten bolts until case extension is fully seated.
2. Position transaxle with case extension facing up. Install Aligning Tool (J-26958) and dial indicator. (Scheme 135) Zero dial indicator. Use Snap Ring Remover (J-28585) or large screwdriver to lift front differential carrier. Pry up on VSS reluctor wheel through sensor hole in case extension.
3. Note dial indicator measurement. End play should be.005-.025" (.13-.64 mm). Record measurement for reassembly reference. If dial indicator reading is less than.005" (.13 mm), install next smaller size thrust washer, and check end play. If dial indicator reading is more than.025" (.64 mm), install next larger size thrust washer, and check end play. For available thrust washer sizes, see «CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES»(ref-131089-S35041388482001121000000) table under TRANSAXLE REASSEMBLY.

Scheme 135

MANUAL VALVE LINK & OIL DAM

1. Remove manual shift detent bolt and manual shift detent. (Scheme 136) Compress manual valve link spring. Lift link off manual valve. (Scheme 137)
2. Position manual valve so valve will not interfere with case cover removal. Remove oil dam from case. (Scheme 138) Using small screwdriver, pry input speed sensor clip out of case cover. Use care when handling speed sensor. Carefully pull input speed sensor out of case cover. (Scheme 139)

Scheme 136

Scheme 137

Scheme 138

Scheme 139

CASE COVER & GASKETS

Remove indicated case cover bolts. (Scheme 140) Hold manual valve in place. Lift case cover and thrust washers off case. (Scheme 141) Remove upper and lower case cover gaskets. (Scheme 142)

Scheme 140

Scheme 141

Scheme 142

4TH CLUTCH SHAFT & PLATES

Remove 4th clutch backing plate, composition plates and steel plates. Remove 4th clutch shaft. Remove drive link lube scoop. (Scheme 143)

Scheme 143

Drive Chain (Drive Link) Stretch Check

Ensure driven sprocket support assembly and both sprockets are fully seated. Pull drive link toward case at indicated location. see scheme 69 Measure distance between case and drive link. If measurement is.126" (3.2 mm) or more, drive link may be reused. If measurement is less than.126" (3.2 mm), replace drive link.

REVERSE BAND & REACTION DRUM

Tilt band to disengage band from anchor pin in case. Remove reverse band. (Scheme 144) Lift reverse reaction drum from transaxle case. (Scheme 145)

Scheme 144

Scheme 145

All Wheel Drive

1. Install final drive sun gear shaft. see scheme 37 Use petroleum jelly to retain parking gear thrust bearing to parking gear. Install parking gear thrust bearing and parking gear. see scheme 36 Install final drive sun gear. see scheme 34
2. Install End Play Checking Tool (J-44472). (Scheme 146) Install bolts and tighten securely to prevent tool deflection during end play measurement.
3. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer to lift input clutch housing. see scheme 72 Install input clutch housing assembly into case. Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input clutch housing.
4. Using 2 bolts, install End Play Gauge (J-33386) onto case. (Scheme 147) Tighten bolts to securely hold end play gauge. Tighten end play checking tool finger tight to eliminate differential carrier end play.
5. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge, measure end play between end play gauge and thrust washer.
6. Record measurement for proper end play clearance during reassembly. End play should be 0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during transaxle reassembly. If end play is greater than.006" (.15 mm), select next size larger thrust washer and recheck. For input clutch thrust washer identification, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(ref-131089-S05760487062001121000000) table under TRANSAXLE REASSEMBLY.
7. Remove end play checking tool. (Scheme 146) Install remover/installer into input clutch housing. Tighten threaded rod of remover/installer until rod is finger tight. Using remover/installer, lift input clutch housing assembly (sprag clutch assemblies will also be attached) from case.
8. Position transaxle so oil pan is facing down. Remove final drive sun gear, parking gear, parking gear thrust bearing and final drive sun gear shaft.

Except All Wheel Drive

1. Install Final Drive/Clutch Remover/Installer (J-33381-A) into input clutch housing and sprag clutch assemblies. Tighten threaded rod until rod is finger tight. Use Remover/Installer to lift input clutch housing. see scheme 72 Install input clutch housing assembly into case. Ensure assembly is fully seated. Ensure selective thrust washer is NOT installed with input clutch housing.
2. Remove remover/installer from input clutch housing. Install case extension with Output Shaft Loading/Aligning Tool (J-26958), Adapter Plug (J-26958-10) and Loading Tool Adapter (J-43425) attached to case extension. (Scheme 148) Using 2 bolts, install End Play Gauge (J-33386) onto case. (Scheme 147) Tighten bolts to securely hold gauge. Tighten aligning tool finger tight in order to eliminate differential carrier end play. (Scheme 148)
3. Install thrust washer from input clutch housing into end play gauge. If thrust washer will not fit into gauge, select next size smaller thrust washer and recheck. Using a feeler gauge, measure end play between end play gauge and thrust washer.
4. Record measurement for proper end play clearance during reassembly. End play should be 0-.006" (0-.15 mm). If end play is within specification, use original thrust washer during transaxle reassembly. If end play is greater than.006" (.15 mm), select next size larger thrust washer and recheck. For input clutch thrust washer identification, see «INPUT CLUTCH THRUST WASHER IDENTIFICATION»(ref-131089-S05760487062001121000000) table under TRANSAXLE REASSEMBLY.
5. Remove end play gauge. Install remover/installer into input clutch housing. Lift input clutch housing from case. Remove aligning tool, adapter plug and loading tool adapter from case extension.

Scheme 146

Scheme 147

Scheme 148

CASE EXTENSION & DIFFERENTIAL CARRIER

Remove case extension bolts. Remove case extension and remove seal. Remove differential carrier thrust washer and thrust bearing. (Scheme 131) Remove differential carrier assembly. Remove differential sun gear shaft. Remove thrust bearing from differential carrier sun gear. Bearing may be stuck to carrier assembly. Remove differential carrier (final drive) sun gear. Remove parking gear. Remove thrust bearing from differential carrier internal gear. (Scheme 149)

Scheme 149

INPUT & REACTION CARRIER

Position transaxle with case cover facing up. Remove input carrier assembly. (Scheme 150) Remove input carrier and reaction carrier lube dam. (Scheme 151) Lube dam may be stuck to input carrier assembly. Remove thrust bearing from reaction carrier. Remove reaction carrier assembly.

Scheme 150

Scheme 151

REACTION SUN GEAR & 2-1 MANUAL BAND

Remove thrust bearing from reaction sun gear. Remove reaction sun gear assembly. (Scheme 152) Tilt band to disengage 2-1 manual band assembly from anchor pin. Remove 2-1 manual band from case. (Scheme 153)

Scheme 152

Scheme 153

1-2 SUPPORT DRUM & FORWARD BAND

Install Support Remover/Installer (J-38358) onto 1-2 support drum assembly. Lift remover/installer with 1-2 support drum out of case. (Scheme 154) Tilt band to disengage band from anchor pin. Remove forward band from case. (Scheme 155)

Scheme 154

Scheme 155

FINAL DRIVE INTERNAL GEAR

Remove thrust washer from final drive internal gear. Use snap ring remover or large screwdriver to remove final drive internal gear retaining ring. Lift final drive internal gear out of case by depressing parking pawl to clear case. (Scheme 156)

Scheme 156

PARKING SYSTEM COMPONENTS

1. Using side cutting pliers, remove manual shift shaft pin. DO NOT cut through pin. Protect case with piece of wood or rubber under pliers when removing pin. (Scheme 157) Remove manual valve link and spring from manual shift detent lever. Remove manual shift detent lever nut from manual shift shaft. Remove manual shift detent lever and remove parking pawl actuator. (Scheme 158)
2. Position transaxle with reverse band servo bore facing up. Pull manual shift shaft out of case. Using small screwdriver, pry manual shift shaft seal from case. Remove parking pawl actuator guide pin. Remove parking pawl actuator guide from case. Remove actuator guide seal from guide. (Scheme 159)

Scheme 157

Scheme 158

Scheme 159

VEHICLE SPEED SENSOR RELUCTOR WHEEL

Note. DO NOT remove reluctor wheel unless damaged.

Functional Check

Position 1-2 support drum on bench. Install reaction sun gear assembly into 1-2 support drum. Rotate reaction sun gear counterclockwise. Rotate 1-2 support drum clockwise. (Scheme 163) Roller clutch should move freely in indicated directions. Roller clutch should lock in opposite direction. If roller clutch does not function as described, clutch is not assembled correctly. Reassemble as necessary.

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Input Clutch & 3rd Sprag Clutch Functional Check

Hold input sun gear stationary. 3rd sprag clutch outer race should rotate only in counterclockwise direction and lock in clockwise direction. Input sprag clutch outer race should rotate in clockwise direction and lock in counterclockwise direction. (Scheme 168)

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Input Clutch & 3rd Clutch Functional Check

Using rubber tipped air nozzle, apply a maximum of 20 psi (1.4 kg/cm 2 ) air pressure at indicated fluid passage holes. (Scheme 182) Ensure input clutch and 3rd clutch apply. If clutch does not apply, recheck component reassembly.

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

INPUT CLUTCH HOUSING CHECK BALL VALVE

Note. Remove check ball valve only if inspection or leak check indicates problem with check ball valve.

2nd & 4th Clutch Functional Check

1. For this test, attach driven sprocket support assembly and 2nd clutch housing thrust washer onto 2nd clutch housing assembly. (Scheme 187)
2. Apply 20 psi (138 kPa) of compressed air to feed holes marked 2 and 4, and listen for 2nd and 4th clutch application. (Scheme 188) Hold pressure for 5 seconds. If clutches do not apply and hold, disassemble driven sprocket support components.
3. Inspect all seals and clutches for proper assembly. Reassemble and repeat functional check. When clutches apply and hold correctly, remove driven sprocket support assembly and 2nd clutch housing thrust washer from 2nd clutch housing assembly. (Scheme 187)

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

DRIVE SPROCKET & TURBINE SHAFT

Note. DO NOT damage grooves under oil seal rings.

CASE COVER COMPONENTS

Note. DO NOT remove any bore plugs unless inspection indicates replacement is necessary.

Cleaning

Clean control valve body thoroughly in clean solvent. Move valves with a pick or small screwdriver to dislodge any dirt or debris. Use air nozzle to dry control valve body and to blow out all passages. Gently probe small passages with a piece of identification tag wire or equivalent.

CASE SIDE COVER

Note. Case side cover gasket and channel plate seal may be reused if not damaged.

TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK

Note. ATF circulates between transaxle and transfer case. In situations where transaxle related failures circulate debris into transfer case, transfer case must be disassembled, cleaned, and inspected for damage.

1. Position transaxle so case side cover is facing down. Install final drive sun gear shaft. see scheme 37 Use petroleum jelly to retain parking gear thrust bearing to parking gear. Install parking gear thrust bearing and parking gear. see scheme 36 Install final drive sun gear. see scheme 34
2. Install bolts to end play checking tool and tighten securely to prevent tool deflection during end play measurement. (Scheme 146) Hand tighten end play checking tool to remove end play. Install gauge bar onto case mounting surface.
3. Measure distance from case mounting surface, bottom of gauge bar to top of final drive sun gear. (Scheme 189) This measurement is dimension "A". Remove gauge bar and end play checking tool.
4. Install gauge bar onto carrier. Measure distance from bottom of gauge bar to transfer case. (Scheme 190) This measurement is Dimension B1. Measure distance from bottom of gauge bar to thrust bearing. (Scheme 191) This measurement is Dimension B2. Subtract Dimension B2 from Dimension B1. This is Dimension "B". For available thrust washer sizes, refer to illustration. (Scheme 192)
5. Remove gauge bar from transfer case. Remove final drive sun gear. Install selective washer. see scheme 35 Install final drive sun gear. see scheme 34

Scheme 189

Scheme 190

Scheme 191

Scheme 192