4T65E-HD Rebuild (with WAY too many pics)

[1fatcat]

I will be overhauling a 4T65e-HD transmission in the near future and wanted to post some pics for you guys. Hope you like it.

After a bath from my pressure washer. Note the plugs at the axle shaft output and vent. All openings should be capped, plugged or sealed in some manner to keep water out when pressure washing. The torque converter was installed when pressure washing to keep water out. There will come a time that the case can be pressure washed inside and out, but that is at a much later stage in the process.


Imagine that, a broken front mount!

[1fatcat]

Drain the torque converter. This will take a few hours to drain, overnight is best.


A trans overhaul will make a mess! Have a clean work area with lots of room to store all the parts that come out of it. A fluid containment work bench works best, but not many folks have one.


Remove brackets, sensors and fill tube.







Mark the stud bolts

Clean the crud out of the torx bolts

Remove the side case

Sometimes the torx bolts round and you need to chisel them loose.

[1fatcat]

Remove wirring harness

Remove pump cover, or assembly if preferred, it will be gone through later.


Remove pump assembly

This is the channel plate after the valve body is removed

Note the location of the check balls

Remove the pump drive

This is after the channel plate is removed

Make sure to keep track of locator pins, they are very important and can not be left out.

[2000Silverbullet]

Up to this point, have you used any special tools or pullers?
Good pictures.
Does everything come out together with the pump cover? I see plungers and solenoids.

[1fatcat]

To this point, there have been no special tools. Unless you consider torx or chisels "special". The pump cover does not hold everything. It comes apart in 3 main layers, the pump, then the valve body, then the channel plate.

[1fatcat]

Remove the chain, sprockets and related parts


The torque converter lock up o-ring must be removed prior to input shaft removal

After chain and sprocket removal

Remove oil baffles


Pan removal

Remove the filter

Remove the spring from the anti bleed valve

Remove the clip from the lube tube

[1fatcat]

After apply piston and accumulator pack removal

Spotted the first big problem, a broken land on a band

Remove the apply piston cover

You may need to tap the c-clip to spin it a little


Push down on the cover to get more access to the clip

Removing the guts





Still no special tools to this point.

[1fatcat]

A nice stack of parts, all of which need to be broken down further, inspected and repaired/replaced as needed

A burned up band

And the drum it rides on

Here is that broken band land. This is not the band that burned

Behind door number 2...

This doesn't look stock to me, I assume it was the cause of or attempted solution to the broken band land

A shot of the differential

Remove this roll pin and plug to replace the o-ring seal inside

[1fatcat]

Another shot of "the pile"

Remove the remaining seals




Use a long, sharp chisel to collaps the seal in on itself. Be careful of the soft aluminum case

A seal puller for the converter seal (the first special tool used (and it's still not that special)


Remove the converter hub if you want, generally you will not need to

[2000Silverbullet]

Seems pretty straightforward so far.
I can see the trick will be remembering the sequence and order of all the parts on re-assembly.

You've done this before a few times haven't you.

[1fatcat]

This ain't my first rodeo.

[2000Silverbullet]

Keep going cowboy. I'm liking what I see so far. I know how hard it is to stop and take pictures as you work without getting caught up in the moment and skip tricky moves.

[1fatcat]

This doesn't look stock to me, I assume it was the cause of or attempted solution to the broken band land

My mistake. That washer is stock. I guess the band just broke from fatigue.

[00Beast]

Very Good thread!! Still not something I would want to tackle unless a pro was standing right there, but cool to see that someone can do it, lol.

[2000Silverbullet]

Confidence Ed, confidence.
You can DO anything.

I would do it, if it was a spare salvaged trani, but probably not if it was my DD and I needed it working in a hurry.

More pics 1fatcat....more pics!!

[1fatcat]

I sure hope there are more posts before I start reassembling. It would suck to load MORE pictures on page 1 (takes forever to open).

[2000Silverbullet]

Yes it does surprise me that more members are not asking more questions and getting involved with this interesting post.



Maybe an admin is able to roll this to page 2.

[sonoma_zr2]

I am interested in more ways than 1.

First, I hope it goes to the second page because I run IE8 in protected modes and it has to download the pics each time I go to the post.
Second, I hope to be getting involved with the post.

[2000Silverbullet]

Ya Travis, you put on enough mileage to rebuild one of these trani's every couple years.

[2000Silverbullet]

......and it's still on Page 1