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Home › Pontiac › 1996 › Grand Prix Base › Repair and Diagnosis › Transmission › Automatic Trans › Automatic Transaxle Overhaul & Testing - 4T60-E › Transaxle Reassembly

Transaxle Reassembly

NOTE: See Fig 8-Fig 11 for disassembly and reassembly reference.
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 ASSEMBLY  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  under TRANSAXLE DISASSEMBLY. See Figure. 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 .
    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. See Fig 1. Install 4th clutch plates starting with steel plate.
    Fig 1: Aligning Channel Plate & 4th Clutch Plate
    G92A13755Courtesy of GENERAL MOTORS CORP.
  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. See Fig 1. Install sleeve into channel plate. Install oil reservoir baffle, detent spring and roller. Install channel plate gaskets.
  12. Install and tighten channel plate bolts. See Fig 2. Install 4 check balls in channel plate, using petroleum jelly to retain check balls. See Fig 3. 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. See Fig 4.
    Fig 2: Locating Channel Plate Bolts
    G94J38470Courtesy of GENERAL MOTORS CORP.
    Fig 3: Locating Channel Plate Check Balls
    G92C13757Courtesy of GENERAL MOTORS CORP.
    Fig 4: Locating Channel Gaskets, Pistons & Thrust Washer
    G96I04304Courtesy of GENERAL MOTORS CORP.
  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. See Fig 5.
  15. Install valve body assembly onto channel plate using alignment pins. See Fig 6. Install servo pipes into valve body using retainer and bolt. Install pump onto valve body assembly. Install pump attaching bolts. See Fig 7.
  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.
    Fig 5: Locating Valve Body Check Balls
    G92H13760Courtesy of GENERAL MOTORS CORP.
    Fig 6: Locating Control Valve Assembly Bolts
    G94A38471Courtesy of GENERAL MOTORS CORP.
    Fig 7: Locating Oil Pump Bolts
    G94G38469Courtesy of GENERAL MOTORS CORP.
  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 Figure. 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.
Fig 8: Exploded View Of Internal Components (2nd Clutch To Final Drive)
G94B38472Courtesy of GENERAL MOTORS CORP.
Fig 9: Identifying Hydra-Matic 4T60-E Thrust Washer & Bearing Locations
G94C38473Courtesy of GENERAL MOTORS CORP.
Fig 10: Identifying Hydra-Matic 4T60-E Lip Seal Locations
G94D38474Courtesy of GENERAL MOTORS CORP.
Fig 11: Identifying Drive Link Components
G96C04320Courtesy of GENERAL MOTORS CORP.
Fig 12: Identifying Shift Solenoid Feed Holes
G96E04477Courtesy of GENERAL MOTORS CORP.
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