DIY automatic transmission repair 4t65

Automatic transmission 4T65E is a modification of the 4T60E transmission produced since 1997 and is designed for cars with front-wheel drive and engines of 2 to 4 liters. The 4T65E automatic transmission is quite reliable and maintainable, and its main problems are associated with untimely replacement of oil and filters, as well as violation of the rules for operating the car. In the Russian market, the 4T65E automatic transmission received its popularity thanks to the Volvo car.

• The first thing to be repaired in these transmissions is associated with wear of the blocking of the gas turbine engine, contamination of the valve body, as well as the solenoids, which leads to a drop in pressure in the packages, causing shocks when switching stages. Brake bands are also replaced.

• The weak point of the clutch packages is the 2nd Clutch package, where you have to either restore or replace a burnt drum, as well as clutches with steel discs.

• Solenoids most often fail: torque converter blocking, pressure, shift solenoid (responsible for switching on 1-2 and 3-4 speeds).

• The valve body gets into repair due to overheated dirty oil and long-term operation of the automatic transmission without its planned replacement. Repairs are performed using Sonnax kits.

• With high mileage, all bushings (set), as well as the seals of the axle shaft (left and right), pump and torque converter must be replaced. The kit also replaces washers (sleeve bearings). The drive chain, bearings, rubberized pistons (2nd and 3rd gear) and less often the differential on all-wheel drive vehicles are replaced.

Reliability of construction

In general, the 4T65E automatic transmission is simple in design, reliable, and if you constantly monitor the ATF oil, then it has a fairly large resource after a major overhaul.

In the early 90s, the American company General Motors developed a four-speed automatic transmission 4T60E / 4T65Ewhich was intended for front-wheel drive vehicles with six-cylinder engines. This modification of the gearbox was installed on crossovers from Volvo and other cars from the manufacturers of General Motors.

The development of this transmission model was based on the well-proven 4T50E model, which has been in use since 1993. It should be noted that the new transmission has established itself as maintainable and reliable in use. The use of special designs, a metal-plastic filter with a felt membrane, made it possible to significantly improve the quality of lubrication and cooling of the transmission. The gearbox turned out to be uncritical to the quality of the oil, which made it possible to save the car owner from the need for maintenance automatic transmission 4T60E / 4T65E... The automatic transmission has a re-tuned shift pattern to optimize the performance of the engine. At the same time, we note that there is no possibility of manual gear shifting in the box, but there is only a special sport mode that reconfigures the gearbox and allows the engine to spin up to maximum speed.

The weak point of this modification of the gearbox is the bearings, which can become unusable already on a run of 150-200 thousand kilometers. As a rule, when the car reaches this mileage, it becomes necessary to overhaul the gearbox. Overhaul is a certain difficulty, which is explained by the need to dismantle the box from the car and carry out repair work at a special stand. In some cases, there may be oil leaks from under-quality gaskets.In this case, the repair consists in replacing the rubber gaskets and cleaning the oil. Quite often, there are problems with the drum clutch, which, when driving aggressively, quickly burns out and requires replacement. At the same time, we note that the capital repair 4T60E does not differ in high cost, but it is necessary to dismantle the gearbox.

An automatic transmission is an expensive component. There is no point in delaying the repair if it starts to work incorrectly. In a car service, such repairs are expensive. You have to pay for the work of specialists and for the details. Having studied the market and the price range of services in this segment, motorists come to the conclusion that repairing automatic transmissions with their own hands is not such a pointless undertaking. The prices of the workshop masters cannot be called modest, and the professionalism does not always correspond to the price. And, after some thought, motorists can decide to fix the problem on their own.

Wherever you decide to repair the gearbox, the whole process goes according to the following scheme:

• diagnostics,
• dismantling the box,
• disassembly of the box,
• complete set with spare parts,
• assembly (installation),
• installation on a car,
• diagnostics after repair.

To fix the problem yourself, you will need some car mechanic skills, tools, a certain amount of time to work with, patience and perseverance.

All automatic transmissions are arranged the same, but there are two types of transmission control - hydraulic and electronic. Their renovation has some differences.

It is important to notice transmission problems at the earliest possible stage. Then, with the correct diagnosis, complex repairs can be avoided. Quiet and smooth operation of the automatic transmission is considered normal. There are a lot of signs that something is wrong with the box. Most often these are extraneous sounds when changing gears or during robotic transmission. It can be crunching, clicks. An unpleasant smell also speaks of problems. It can appear during long-term or short-term operation of the box. It is worse if the gear shifting slows down, or one of them does not work at all. Then immediate intervention is required.

Do not be lazy to look under the car, it should be clean there. Red spots will indicate an oil leak from the transmission. Checking the oil level regularly is a must. Normally, it should be translucent, reddish in color. No burning smells or muddy shades! If they appear, it's time to change the oil.

Automatic transmission malfunctions often arise due to improper operation. The transmission becomes unusable due to insufficient oil level or overheating. For this reason, the gears wear out, the machine can jerk when changing gears. As a result, any part of the automatic transmission may fail. Shocks when driving indicate overheating of the oil and the appearance of problems in the valve body.

Aggressive driving with hard acceleration and braking will erase details. Does not add durability to the box and driving in traffic jams, slipping. All this leads to overheating of the box and has a bad effect on its general condition.

All faults are divided into two subgroups. They can occur in

• electronic control system,
• mechanical and hydraulic parts of the gearbox.

If a malfunction occurs, the automatic transmission goes into emergency mode, that is, it goes into third speed and does not switch. The corresponding icon appears on the display.

If problems have arisen with the electronics, then it will not be possible to fix them by repairing the automatic transmission. Therefore, it is important to understand the nature of the faults.

In diagnostics, the main thing is to collect the necessary information and interpret it correctly. Therefore, it is better to consult a specialist. Determine what the problem is at the service station, and take care of the repair yourself. Without proper experience and equipment, you will spend a lot of time on diagnostics. There are mechanical and computer diagnostics.

General scheme of diagnostic procedures:

• check the oil,
• check the operation of the engine at idle speed, the connection points of the wiring and cables,
• determine the error codes of the operation of the control units (CU) of the gearbox and engine,
• check the box on a car without movement,
• check the automatic transmission in motion,
• check the pressure inside the control system.

If the cause of the malfunctions is electronics problems, then most likely you will not need to dismantle and disassemble the automatic transmission. Diagnostics of malfunctions in this system is carried out by the control unit. It monitors the sensor signals, the transmission ratio and the resistance of the output circuits. Malfunctions of such parts and assemblies may occur:

• input sensors,
• electronic control unit,
• executive devices of the control system,
• violation of the integrity of the electrical wiring connections.

The transmission computer receives signals from various sensors. If some parameters are out of order, it writes the code of this problem (DTC) into memory. You can decrypt such numbers using a special scanner.

These are the main problems of the automatic transmission itself. They are conventionally divided into three subgroups:

1. Damage to friction groups, bushings and housings, calipers, planetary gear sets, pump and other mechanics.
2. Defective transformer. This includes:
   • breaks in the splines of the wires,
   • mechanical destruction of the blades,
   • overrunning clutch,
   • wear of the main blocking clutch,
   • depressurization of the piston oil seal.
   • Problems with the mechanics of the hydraulic plate.

If the diagnostics were successful and you cannot do without dismantling, then we proceed to this stage of the automatic transmission repair.

You will need a special lift, or at least a viewing hole. As well as a transmission jack and a set of keys. It is better to perform this procedure in a specially equipped garage or box. It will not be superfluous to invite several physically strong guys to help you move the removed box. Its weight is beyond the strength of even a very strong person. Further action plan:

1. disconnect all communication tubes and cables;
2. unscrew the torque converter mounting bolts, as well as the motor flywheel membranes;
3. remove and move the gearbox;
4. assess the scale of the breakdown and start repairing.

Before removing the gearbox, the oil does not need to be drained from it. However, then do not forget to substitute the container at the place where the oil supply pipes are attached when you disconnect them - otherwise you will get an ugly puddle under your feet.

All actions must be careful. Sudden movements can damage the splines on the input shaft of the diaphragm.

It is better to do automatic transmission repair with your own hands, having it at hand proprietary manual and a printed diagram of the gearbox. First you need to inspect all the systems that serve the gearbox, mounts and blocks. Then we proceed to the repair. For this:

1. We disassemble the gearbox, wash and dry the parts and check them for defects.
2. We change all gaskets, seals, as well as worn out parts.
3. Remove the inhibitor block and sump. We clean out the dirt inside. It looks like metal magnetic shavings.
4. We remove the wiring of the ring from the plug and push them inside the plug.
5. Remove the valve body, loosen the brake band bolts. We wash the valve body.
6. We check the clutches, gears and planetary gears for wear. We will replace it if there is such a need. All internal rubber bands must be changed!
7. We open the oil pump. We check all the details, especially the filter. We change what has already served its term. We use the manual so as not to swap parts.
8. We take out the valves and springs. We wash the valves. Their sticking can be the reason for incorrect operation of the automatic transmission. Replace the accumulator springs if they are broken.
9. Putting everything back into place. It is important not to confuse anything!
10. We replace rings and friction bolts.
11. We check the gear shift assembly and the large piston and put the oil pump in place.

Assembly takes place upside-down.

There are some points that it is advisable to take into account when repairing. Often a transmission problem is related to the filter. It will not be possible to change it without removing the valve body. And when it is removed, the gasket breaks. To replace it, you will need to disassemble the valve body completely.The same applies to the accumulator spring from first to second gear. A special stopper does not allow you to remove it without disassembling the valve body. All valve body gaskets are very similar, do not mix them up. Assembling the valve body, we tighten it with a torque wrench. It is important not to overtighten here.

If all the breakdowns are eliminated, we install the automatic transmission. The moment is responsible, haste is inappropriate here. During these works, the following recommendations should be adhered to:

• When installing the automatic transmission in its place, the diaphragm is checked for end runout using an indicator head. If such a defect occurs, then it must be replaced.
• The radiator is flushed until the gasoline is clean. Then a liter of transmission oil is poured into the gas turbine engine and put on the input shaft. You need to achieve a secure connection and a complete fit. Then you need to dock the engine with the box along the guide centering pins. The crankcases must abut completely.
• Tightening the bolts in the box is the next step. After that, the absence of gaps along the entire plane is checked. After connecting all the highways, the correctness of the connections is checked.
• At the final stage, oil is poured and the operation of the automatic transmission is checked at low engine speeds.

Beginning the installation of the box, be sure to check for the presence of centering pins on the crankcase flange - there should be two of them. If at least one is missing, the automatic transmission cannot be attached.

Automatic transmission repair and diagnostics do it yourself - not an easy, but feasible task. Choosing a car with an automatic transmission, novice car enthusiasts believe that repairing it at home is impossible. This is not true. But before deciding to carry out such important work at home, you need to weigh all your possibilities. Then you will not be in for unpleasant surprises during the renovation.

Repair of any automatic transmission from 1 day

CVTs, DSG, torque converters, new and remanufactured automatic transmissions, spare parts

Well, here it is clear what the conversation is about.

# 1 Post dromanchukoff Mon Sep 20, 2010 2:35 am

# 2 Post FedosovS »Mon Sep 20, 2010 4:48 am

# 3 Post dromanchukoff Mon Sep 20, 2010 12:40 pm

# 4 Post connecting rod Mon Sep 20, 2010 5:36 pm

yes, practically none. and the piston of the third gear is, apparently, a very weak point

# 5 Post Rodser Fri Sep 24, 2010 7:40 am

# 6 Post dromanchukoff Sat Sep 25, 2010 7:11 pm

Shuster - Often remembered will say MORE DEAR FOR YOURSELF

so I butted it out of the kindness of my soul, another word as it is. al during troubleshooting I can’t find 2nd, weighed in the trash, steel and freaks differ only in the direction of the teeth (inward or outward)
also an acquaintance asked me to do everything at a run, now I need to explain somehow that I still need money for steel and it will be current on Tuesday, and on Monday I was thinking of releasing it
Once again I am convinced that there is no need to do * bratzki, the car is desperately needed *, it is necessary as for everyone - well and thoroughly.
now the question is why the 2nd is lit-share, I suspect the bushings, is it so
also for a set of bushings apparently ask for money

# 7 Post primchik Sat Sep 25, 2010 7:19 pm

4-speed automatic transmission 4T65E based on the successful 4T60 (440-T4) transmission. In 1991, it was updated for front-wheel drive cars with an engine from 2 to 4 liters and after running-in, since 1993, General Motors has been supplied for Volvo with a 6-cylinder engine of 2900 cm³. 4T60E after the modification of 1993 became known as 4T65E.

From 1994 to 1998, modifications continued for 4T65E, affecting the hardware, the pallet and, most importantly, the new valve body.

And in 2001 - 2003, the final upgrades were made to the control part of the transmission.

A proven reliable machine from General Motors, which runs confidently for the first 5-7 years of a car's life. Progenitor 440-T4 departed from 1983 on Cadillacs as 4T60, has established itself as quite comfortable and maintainable.

In the Russian market of automatic transmission overhaul 4T65E common in repairs due to the uniqueness of Volvo cars.In terms of the popularity of overhauls among all American automatic transmissions, it comes right after the leader of BMW - 5L40E.

Pick up repair kits for repair - press the button on the left.

The filter - combined metal-plastic with a felt membrane - No. 206010 for 4T65E has remained unchanged since 1991.

The same was used for the American predecessor 4T60E.

Oil - any type of Dexron-III or higher. It is unpretentious to the type of oil, but it is demanding on the purity of the oil, therefore the manufacturer of the boxes recommends changing the oil annually for age automatic transmissions. And if in "youth" there is a recommendation to change the filter with an oil change after one change, then as the components wear out, the oil becomes more contaminated and then the filter is changed with each oil change.

Typical faults automatic transmission 4T65E / 4T60E

Torque converter 4T65E usually quite problematic to repair and “cut” at each bulkhead of the box - 206001.

The repair kit for gaskets and seals has options for years of manufacture and type of car: - 206002.

Usually, craftsmen order non-original Repair kits for gaskets and seals (Overol Kit) from Transtek - No. 206002. More experienced ones more often order budget Overols - ATOK. All repair kits are worked out and do not cause any complaints from the masters. For the 4T60 bulkhead, the more demanded steel Overola from Presision.

Together with a repair kit for gaskets, order a complete set of clutches No. 206003. The repair kit is matched to Volvo machines.

There are options taking into account the difference between the disks of the Forward package and the 4th gear, according to the year of manufacture (from 1999 - 2003 - after) and the car model.

Steel wheels, too, if changed, then the whole set - 206004.

Often MasterKit - 206007 is ordered for a complete bulkhead.

Differential 4T65E

- Bearings in 4T65E - weakness. After 200 tkm runs, they can collapse at any moment.

The first to fail are bearings - 206229B (2nd Clutch Drum to Input Drum), - 206298 (Driven Sprocket Support), - 206247 (Differential).

Differential bearing 247 causes the most costly problems - it breaks the differential sun gear (618), and with it the differential satellites and ring (598). Further, with the flow of oil, metal fragments can damage the rubber seals and the hydraulic plate.

To repair the differential order - Repair kit No. 206716K.

Clutch Drum 2nd Clutch, Input

Of the clutches weak point 4T65E There are two clutch packages: 3rd Clutch with one-way clutches 106-126 and - 2nd Clutch, Input, where you have to change the burnt out Drum Input - 206554. (clutches - No. 206104).

The problem is in the rubbing of the grooves with Teflon rings No. 179, which work at the limit in this modification. The clutches of this transmission (2nd) are the "hottest" and if they have been working for a long time, they most often order a new drum 206552 with them. Thrust discs 206144 and 206145 also have to be changed frequently.

In the same weak node, the 3rd Clutch package may also have problems. One-way clutches are burning - 206126 and 206106 of the 3rd speed package in this drum. They are also associated with vibrations and drum skew during the maximum torque from a 6-cylinder engine and wear of the rings, from under which oil escapes, reducing the pressing of the clutches to each other.

Other popular replacement parts:

- Pistons rubberized packages 2nd gear (206962A) and

The first overhauls consist mainly in the repair of a torque converter with a worn lockup, bulkhead and cleaning of the valve body and solenoids, which can also lead to a loss of pressure in the packages and jerks in gear changes.

When the box came for repair with burnt oil, all three brake bands are changed with the clutches, Forward / LR (Rear) - No. 206022,

And a little less often - brake tape Reverse 206024.

Valve body 4T60E (206740) has many design differences with the block 4T60E , and also really dislikes contaminated overheated oil and a broken differential. The body of the hydraulic plate is being repaired using Sonnax “Boost 4T65E Valve & Sleeve Kit” (206741A).

In mild cases of valve body wear, the plate is most often cleaned and the worn out solenoids are replaced (below). In advanced cases of prolonged operation with dirty oil and a broken differential bearing, the hydraulic plate itself has to be changed.

Differences between valve bodies of different years of production - in the diagram on the left.

From electrics, a relatively short resource for solenoids (it is recommended to monitor their work after 150 tkm of run):

- TCC solenoid lock-up torque converter ( top right ) No. 206425A,

- Main pressure solenoid EPC, (at the bottom) No. 206431A. The resource of all solenoids is approximately the same - sometimes they are ordered as a whole set (4 pcs.).

They change a little less often, but also often - Shift solenoids, (a pair - shifters A and B, are responsible for switching speeds) No. 206421.

Together with them, the Switch is also replaced - the gear shift pressure sensor. No. 206442. The sensor is responsible for indicating gears on the scoreboard. Different before 2003 and after.

In the case of a major overhaul of an aged car with runs much over 200 tkm, the worn out sleeves change, which are usually ordered with the entire set - No. 206030.

Side cover gasket for 4T65E - metallized 206301 is not included in the gasket repair kit.

The gasket is single, in contrast to the double gasket in the younger brother (Inner - internal and Outer - external) 4T60.

Bushings usually fail along with leaking oil seals:

- Oil seal Left 206077 and Right 206076 half-shaft, Pump (GDT) No. 206070 (everyone enters the Overol Kit).

The oil seals of the gas turbine pump in 4T65 - changed in 2000 and differ in height. Included in the Overol Kit repair kit.

- Plastic washers (washers / plain bearings -on right) - change in age machines with the whole set - 206200. They become fragile from summer overheating and can begin to crumble at any time (their resource is determined at 8-10 years).

- Repair of the oil pump is carried out by replacing the pump blades - (206533).

- Drive chain, (Includes a pair of chains) - No. 206700.

Stretching over time and overload.

The box is very simple, reliable and its resource after overhaul is quite large, if you monitor the cleanliness of the ATF oil and do not overload the box with maximum torques.

Problems are encountered primarily with the XC90, which uses a differential in the design. Volvo with this transmission is not designed for off-road driving and unclean roads.

The cost and availability of the items you need can be checked in the online store by clicking the number on an orange background to search for a part.

On which cars this automatic transmission family was installed:

The automatic gearbox significantly improves driving comfort. Smooth shifting in automatic mode allows matching the engine load, driving speed and pressure on the gas pedal, thereby protecting the engine and chassis from overloading.

Automatic transmissions differ in the type of transmission control system used. There is control by means of a special hydraulic device and by means of an electronic system, we read a variator or an automatic machine. Otherwise, all "machines" are almost identical.

The transmission requires diagnostics and repairs if the car slips heavily or when the gear is switched on there are extraneous noises, vibrations, or shocks. Also, a leak or darkening of the oil should be alerted, we read about how to check the oil level in the automatic transmission here, the absence of any gear activation or the flashing of the alarm indicator. Automatic transmission repair is a serious business that requires special skills and knowledge. But the dismantling and installation of the unit is within the power of many motorists. Performing these operations on your own significantly reduces the cost of repairing the "machine" as a whole.

Attention! Car service network of favorable prices. Camber check is FREE! No queues! Repair on the same day!

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As the car service workers joke, they themselves are afraid of cars in which the automatic transmission has broken down. What if such a nuisance happened to your car?

Earlier we already wrote that an automatic transmission is a complex device, and it is better not to undertake its own repair, but not everything is so scary.If you are not afraid of a screwdriver and a key, and also did not have time to bring the automatic transmission to complete depletion, then you can return it to its former power without outside help.

You will have to go to the service station if you probably know that you drove for a long time with a slipping box, which led to damage to the friction units or other malfunctions. Before taking on the transmission, also check if the car's engine is working properly: idle speed should be adjusted and the pedals should not jam at all.

Then proceed to check the fluid in the automatic transmission. It will be sad if it smells bad and has an unnatural color. This means that the "machine" is clearly damaged. You should never skimp on liquid, no matter how much it costs. If there are bubbles in the liquid, this means that it has been poured too much, and upon contact with rotating parts, the "oil" foams. If the liquid has a milky color, then water constantly gets into it, which is also not very good. An option such as a liquid leak is also possible. The reason for its low level is often an oversight of the car owner or damage to the pipes that connect the box and the radiator.

A car with automatic transmission has a cable that can help eliminate the malfunction. The cable connects the gearbox and the carburetor throttle. If it is weakened, then the desired gear is included either late or early.

Check to see if the cable moves freely and does not break in the area of ​​the ferrules. The box has problems if this cable is loose or pinched, but usually it is enough to clean this part of the dirt, lubricate and position so that the cable bends have a large radius.