I rebuilt a 4t65e from a 1999 pontiac montana minivan...I thought I did everything right but i missed something.

1st, reverse, and 3rd all apply and hold okay. There may be some minor slipping, but nothing noticed during road test.

2nd goes in but pops back out under any throttle.

4th will not engage.

TCC does lockup in 3rd.

There is no significant mechanical wear on any metal part that went into the trans on rebuild (everything within the spec. listed in the chassis service manual), I am 100% certain of this. I did have 2 mystery bolts left after rebuild, so yeah. They have different style head and shank than everything else but same thread. I couldn't find any reference to them in the service manual. I didn't photograph any of the tear down... best described as about 65mm long, threaded the length of the shaft, head is hex shape with no washer shape. All other bolts have a washer shaped into the bolt head and are threaded only part way. Again, no reference to them in the service manual...

During road test, shifting from 1st to 2nd: 1st releases, won't apply 2nd until throttle is light. 2nd will hold under feather throttle but releases under light throttle. It's not slipping, but shifts out to a neutral. 2-3 will upshift. Can accelerate for a 1-3 upshift. 3rd holds fine and the tcc will engage. But when shifting to 4th, 3rd will let go and stays in a neutral. 4th never engages. Tried 0-35 in 1st, 35-65 in third, downhill allowed the 3-4 upshift under feather throttle. Still would not shift. Fluid level indicates full. After the road test I could smell hot trans fluid, but could not find any leaking.

Anybody know where to start? I'm do not want to mess it up any further by driving it anymore.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Did you truly rebuild this trans or just inspect it and reassemble?

There are lip seals and Teflon rings that can have issues in the trans... As well are we talking about using this trans in a Bonneville? Or is it still in the van?

I rebuilt it: New clutch fibers and steels, new thrust bearings, thrust washers, springs, seals, filter. The soleniods were working when bench tested. The only thing that was a pain to replace were the 2 teflon ring seals on the input housing shaft. the trans is still in the van, and the pump doesn't whine. The only metal part that had broke was one of the thrust bearings, and the original 2nd and 3rd clutches were burnt and the seals leaked.
The old trans we have out now suspends the shift adapt and sometimes 4th after its warmed up, and the pump whines, and i think the chain jumps.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67

Does anybody have the fluid flow diagrams for the 4t65e in the 4 forward drive ranges? My service manuals don't have such information.

_________________
Boost addict


The Fleet:
'93 SSEi - Twincharged + manual Build thread
'97 Camaro - Top swap
'05 STS - V8, AWD, her DD
'92 Trofeo - Fair weather DD
'99 Montana - top swap 3800
'04 Sierra 2500HD - LLY Duramax

Current project:
Something cool, trust me.

Upcoming projects:
'92 Bonneville SSE
'87 LeSabre T-type
'67 LeSabre

Gone to greener pastures:
'84 Sierra Classic - Twin turbo 3800
'97 LeSabre - Top swap

RIP:
'86 LeSabre - pictures
'93 SE - L67