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DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSBUICK1998REGAL 25TH ANNIVERSARY EDITIONREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONAUTOMATIC TRANSAUTOMATIC TRANSAXLE OVERHAUL & TESTING - 4T65-ETRANSAXLE REASSEMBLY
1998 Buick Regal 25th Anniversary Edition
Transaxle Reassembly
1998 Buick Regal 25th Anniversary EditionSECTION Transaxle Reassembly
NOTE:
End play checks performed during TRANSAXLE DISASSEMBLY procedure must be rechecked at appropriate reassembly stage. For thrust washer, thrust bearing, bushing and seal installation direction and location during reassembly, see Fig 1-56.
- Install and ensure sun gear shaft, forward band, 2-1 manual band, reaction sun gear and reverse reaction drum are in place. Ensure 2-1 manual band anchor pins engage band, and 2-1 manual band assembly stop is in place.
- Check front differential carrier end play. See FRONT DIFFERENTIAL CARRIER END PLAY CHECK under TRANSAXLE DISASSEMBLY. See Figure. Install appropriate thrust washer onto input shaft and hold in position with petroleum jelly. See CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES table. Install sprag, roller clutch and input sun gear assembly into input clutch assembly. Clutch hubs must engage clutch plates.
- 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.
- Check input clutch housing end play. See INPUT CLUTCH HOUSING END PLAY CHECK under TRANSAXLE DISASSEMBLY. See Figure. Using feeler gauge, check clearance between thrust washer and end play gauge. Clearance must be .0-.006" (.0-.15 mm). If clearance is not as specified, use different thrust washer. See INPUT CLUTCH THRUST WASHER IDENTIFICATION table.
- 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.
- 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 snap ring onto output shaft. See Figure.
- 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.
- Install thrust washer onto drive sprocket, and hold washer in position with petroleum jelly. Install sprockets and drive link chain onto case. If original drive link is reused, ensure drive link is installed in same direction as removed. Check drive link stretch. See DRIVE LINK STRETCH CHECK under DRIVE & DRIVEN SPROCKETS in TRANSAXLE DISASSEMBLY. If NEW drive link is installed, install with master link facing upward.
- Install thrust washer onto driven sprocket and retain with petroleum jelly. Insert 4th clutch hub and shaft through driven sprocket, and install 4th clutch plates starting with steel plate. See Figure.
- If necessary, pry out axle seal, and tap NEW seal into place. Install pistons and pins into case cover. Install springs into case cover. Install case cover gaskets. Install thrust washer onto case cover. See Figure.
- Install case cover onto transaxle case. Case cover lugs must align with tangs on 4th clutch plates. See Figure. Install and tighten case cover bolts. See Figure. Install 4 check balls in case cover, using petroleum jelly to retain check balls. See Figure.
- Install NEW case cover/spacer plate gasket onto case cover using alignment pins. Install spacer plate onto gasket. Install NEW control valve body/spacer plate gasket onto spacer plate. See Figure.
- Install oil pump drive shaft. Install 6 check balls into control valve body assembly. Use petroleum jelly to retain check balls in place. See Figure.
- Install control valve body assembly onto case cover using alignment pins. See Figure and Figure. Install control valve body bolts and tighten to specification. See Figure. Install servo pipes into control valve body using retainer and bolt. Install oil pump onto control valve body assembly. Install oil pump bolts. See Figure.
- Install gasket and channel plate seal onto transaxle case and case side cover. See Figure. Install electronic components and wiring harness. Ensure wire connectors are installed in correct locations. See Figure. Install case side cover. See Figure.
- Install accumulator piston pins into case. Install accumulator springs into case. Install accumulator cover, pipes and retainer onto case as an assembly. Install lube oil pipe retainer onto lube oil pipe. Install oil hose and clamps onto lube oil pipe. Install lube oil pipe into accumulator housing. 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.
- Ensure lube oil pipe is installed into differential carrier internal gear. Install NEW oil filter seal, oil filter and pan gasket into case. Install oil pan. See Figure. 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 retaining ring and cover bolts. See Figure. Install vehicle speed sensor. Use Converter Holding Strap (J-21366) to hold torque converter in place during transaxle installation.
CARRIER-TO-CASE SELECTIVE THRUST WASHER SIZES
| Washer ID No. | Color | Thickness: In. (mm) |
|---|---|---|
| 1 | Orange | .055-.059 (1.40-1.50) |
| 2 | White | .059-.063 (1.50-1.60) |
| 3 | Blue | .063-.067 (1.60-1.70) |
| 4 | Pink | .067-.071 (1.70-1.80) |
| 5 | Brown | .071-.075 (1.80-1.90) |
| 6 | Green | .075-.079 (1.90-2.00) |
| 7 | Black | .079-.083 (2.00-2.10) |
| 8 | Purple | .083-.087 (2.10-2.20) |
| 9 | Purple/White | .087-.091 (2.20-2.30) |
| 10 | Purple/Blue | .091-.094 (2.30-2.40) |
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 | No Color | .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) |
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.