- Disassemble
4T80-E TRANSAXLE
1. Remove speed sensor bolt, then speed sensor and seal.
2. Remove cooler fitting and seal.
3. Remove three bolts from 4th servo cover. Hold servo cover in place until all bolts are removed. If cover is not held in place, apply pin will damage bore in case.
4. Remove cover and servo assembly.
5. Measure final drive end play as follows:
a. Position dial indicator with stem contacting output shaft. Zero dial indicator.
b. Insert snap ring remover through output speed sensor bore and lift speed sensor rotor for measurement. Protect bore with a piece of wood or used filler tube seal.
c. Proper endplay clearance is 0.15-0.65 mm.
d. Record measurement and if necessary, adjust with proper thickness selective thrust washer when assembling.
e. Remove dial indicator.
6. Remove case extension bolts and stud, then case extension and seal; seal may remain in extension.
7. Remove roller thrust bearing and selective thrust washer, then scavenger tube bolt, tube and tube seal. Remove tube by prying on differential.
8. In order to remove final drive assembly and output shaft, transaxle must be in Park with differential locked in place. If differential can rotate, turn manual shaft counterclockwise to Park position. Actuator rod will stick out of case.
9. Remove differential bolts, then differential carrier.
10. Push on output shaft to expose snap ring, then remove output shaft snap ring.
11. Remove left side differential gear, then pull output shaft through opposite end of case.
12. Remove left thrust washer, final drive carrier, then thrust bearing.
13. Remove final drive sun gear, snap ring, then final drive internal gear.
14. Remove bottom pan bolts, bottom pan and gasket.
15. Remove scavenge screens and seals.
16. Using a screwdriver, disconnect shift solenoids A and B and transaxle pressure switch connectors by prying back on tabs.
17. Remove oil transfer plate bolts. Wiring harness retaining clips will remain with wiring harness. Remove oil transfer plate.
18. Remove manual valve linkage clip using a screwdriver, then remove lower controls assembly bolts (except those indicated in the image).
19. Lift lower channel plate, valve assembly and accumulator assembly from case as a unit.
20. Measure input shaft endplay as follows:
a. Install input shaft endplay lifting tool No. J-39686, or equivalent, into case barrel and post Locate J tab on input shaft. Arrow on tab should have 90° orientation. Washer must rest flat on case cover seal
b. Rotate threaded shaft clockwise until tight. Leave enough space for collar.
c. Insert collar, then install dial indicator. Push down on handle and check endplay. Endplay should be 0.10 - 0.85 mm; if measurement is out of specifications, determine appropriate selective thrust washer for installation during assembly.
d. Remove dial indicator, input shaft lifting tool and post
21. Remove side cover bolts, side cover and gasket.
22. Remove main filter and seal. Seal may remain in secondary pump body (use screwdriver to pry out).
23. Disconnect temperature sensor, ICC solenoid and pressure control solenoid (insets in image) by prying back tabs.
24. Remove pump housing bolts indicated, then remove scavenge, primary and secondary pump assemblies.
25. Remove upper control valve body bolts, then upper control valve body assembly.
26. Remove spacer plates and gaskets, then two check balls from case cover.
27. Remove case cover bolts and studs, then case cover. Pass wiring harness through case cover since it will remain in case.
28. Remove case cover gasket and island gasket.
29. Remove thrust bearings from drive and driven sprockets.
30. Remove drive sprocket and turbine shaft assembly, driven sprocket and chain. Mark chain to indicate direction in which it was removed. If chain is installed upside down, noise may occur during vehicle operation. Pry off driven sprocket using two screwdrivers to hold in place, then tap drive sprocket and turbine shaft off using a plastic hammer.
31. Remove six drive sprocket support bolts, then drive sprocket support. It may be necessary to tap support off using a plastic hammer from bell- housing side. Remove driven sprocket support assembly. Ensure scavenge tube seal stays in support when tube is removed. If not, inspect tube case area for dislodged seal.
32. Remove bolts from speed sensor and retainer.
33. Disconnect input speed sensor and harness. Pass through connector and wiring harness assembly from case; remove by pushing three tabs inward from outside of case.
34. Remove 2nd clutch plates. Push up near scavenge tube channel and bottom pan side.
35. Remove reverse clutch support thrust washer, then reverse clutch housing and 2nd sprag assembly. Grasp 2nd sprag race to remove.
36. Remove 4th band, then 3rd clutch and reaction carrier assemblies. Grasp input shaft to remove 3rd clutch and reaction carrier assembly.
37. Remove reaction carrier shell.
38. Move manual shaft from Park position, then drive out pivot pin retaining pin. Only early 1993 models used a retaining pin and pivot pin with a notch for retaining pin. Later models use a longer and straight pivot pin without a retaining pin.
39. Drive parking pawl pivot pin towards side cover with pin punch. Push down on spring while driving shaft.
40. Remove parking pawl and spring.
41. Remove actuator park lock sleeve using a rubber mallet. Drive out towards case extension portion of case.
42. Remove forward clutch support bolts from case, then install forward/coast clutch puller tool No. J-39053, or equivalent. Secure and lift forward coast clutch assembly out of case with chain hoist or suitable lifting equipment. Forward/coast clutch assembly weighs approximately 50 lbs.
43. Remove fretting ring and b/reverse band.
44. Remove detent spring. Grasp detent roller end of spring with pliers to remove.
45. Remove detent roller bolt pivot arm, sleeve and washer.
46. Remove manual shaft nut. Detent lever must be held in place when removing nut to prevent damage to actuator rod.
47. Remove detent lever and actuator rod. Discard detent lever, it is not reusable.
48. Remove manual shaft, seal and washer. Move out through top of bellhousing.