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19CommentsJoined November 9th, 2014
I am an alternative energy technician in western S.D. . / consultant for renewable energy systems,systems designer and construction and maintenance. I manufacture some custom electronics assemblies .along with several activities.
  • How to rebuild a 1997-2003 4t650e-HD transmission

    Saw where it was mentioned to add a drain plug. Not really worth the effort. These pans don't have a small sump spot. If you add a drain plug to these pans, it will hang down and can take a hit and cause even more trouble. Everything is already so low under here.

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  • How to rebuild a 1997-2003 4t650e-HD transmission

    .003 of an inch is not the much and this spring is not going to notice that much difference. That spec you see in the manual is a close shot in the ball park. I think by filing both ends of this spring, you pretty much when to a small amount of wasted effort. Not going to cause any issue because you did it either. Just a matter of being just a bit too particular here.

    Yes the computer must be reprogrammed if you change the final drive ratio. It costs around $500 for the software pack that will let you access the computer and re flash it. I would not recommend trying the dealership to have this done either. There are a few outfits that specialize in this stuff that will re program your PCM to you preferences, do a google search for 3800 performance and take your pick. I don't know if it's acceptable to advertise for any of those places here, that's why I haven't made any recommendations. There are 2 sensors in the trans that signal the PCM what the input shaft is doing and the output also. When you change the ratio, there will be a difference in the signal frequency that the PCM will see and cause issues. Once you decide who you want to program your c...

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    Yes the computer must be reprogrammed if you change the final drive ratio. It costs around $500 for the software pack that will let you access the computer and re flash it. I would not recommend trying the dealership to have this done either. There are a few outfits that specialize in this stuff that will re program your PCM to you preferences, do a google search for 3800 performance and take your pick. I don't know if it's acceptable to advertise for any of those places here, that's why I haven't made any recommendations. There are 2 sensors in the trans that signal the PCM what the input shaft is doing and the output also. When you change the ratio, there will be a difference in the signal frequency that the PCM will see and cause issues. Once you decide who you want to program your computer, they will ask you for various parameters to assist them in getting the program file constructed and or they will give you a standardized file.

    Assembling this into the case is easier if you can stand the trans case up on a table so the diff end is up. After you install the planetary support and snap ring. Put your selective spacer and all the bearings in their places and put the case cover on. Next you can turn the trans over and let the main part of the case where all the internals go, hang down over the edge of your table and support it with a bucket or something that is the right height, use a clamp or some pins or anything that you can put in the top of the table to hold the case secure and set all the rest of the pieces in the case. Trying to put all of the parts in the case with it laying on the bench in close relation to how it goes in the car is pretty hard to do and get all the parts fit together.

    If your referring to the ones between the engine block and the trans, up close to the cylinder head, you need a long extension with a floppy joint and the socket that fits the bolts. Remove the tire on the passenger side and shine a light up in there. Reach in with your extension and socket and get it on the bolts. They're a bit tough to get to. I have seen a few that have had the transmissions worked on before I got to them and SOME shops will leave them out just because they are so hard to work with. I HATE that kind of work ethics. IMO> if the factory deemed it necessary to design it with a bolt there, PUT IT BACK when you get to that point ! Leaving bolts out of places like this are what causes bell housing to break and then the torque converter/ bushings and basically the entire...

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    If your referring to the ones between the engine block and the trans, up close to the cylinder head, you need a long extension with a floppy joint and the socket that fits the bolts. Remove the tire on the passenger side and shine a light up in there. Reach in with your extension and socket and get it on the bolts. They're a bit tough to get to. I have seen a few that have had the transmissions worked on before I got to them and SOME shops will leave them out just because they are so hard to work with. I HATE that kind of work ethics. IMO> if the factory deemed it necessary to design it with a bolt there, PUT IT BACK when you get to that point ! Leaving bolts out of places like this are what causes bell housing to break and then the torque converter/ bushings and basically the entire transmission is junk again. The one I am rebuilding right now is from a car that had the engine swapped out and the guy that did it is working at a shop where one of the other guys that has been working there used to work for me in heavy trucks, I trained him better than that I thought.

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  • How to rebuild a 1997-2003 4t650e-HD transmission

    Yes those clamps will dimple the rings, one way to do this is to use a piece of an aluminum can cut and folded so there are no sharp edges and use a hose clamp to size them. The rings will shrink a little and then expand a little when you release the clamps. Be very careful when you assemble the hubs into the trans. All the places these rings go into have a slight chamfer so just a little larger rings is a good thing to have, makes for a good seal.

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