2003 4L60e - Input Shaft End Play

.- New member here and first post. I've searched and read through relevant posts and
could not find a solution to my issue.

I'm currently re-assembling this transmission after a 3-4 clutch burn-up and I'm
having trouble establishing input shaft end play. There isn't any. There wasn't any
end play prior to tear down either. Perhaps because of the warped and broken 3-4
clutches?

During disassembly, I compared the order of the removed components with my ATSG
manual and all seemed to be OK. I also took photographs.

During re-assembly, I had no difficulties with installing the low/reverse clutch support
retaining ring in the case groove or with the output shaft snap ring. I'm assuming that
the component stack-up in the case is correct.

All my clutch pack clearances measure within specs and none needed any "persuasion"
to get their retaining rings installed.

I did not replace the pump stator shaft. I just replaced the two bushings.

I trial fit the input/reverse input assembly into the case along with the pump numerous
times to try to find the missing clearance. I've confirmed that the input sun gear is
riding against the bearing inside the input planetary carrier. The reverse input drum
bushing that's facing the pump is installed against the inside lip of the drum.

In order to see just how much end play that actually exists, I removed the selective
washer (I left the bearing in place) and the input shaft end play measured 0.020". I
don't think leaving out the selective washer is an option. The transmission was built
with a No. 69 (0.091" thick) washer. The input shaft does turn with some effort when
assembled with the washer (I know this is totally subjective).

BTW, I know the transmission was never opened or messed with; I'm the original
owner of the vehicle.

Not having any end play prior to disassembly is worrisome and strange. If anyone can
comment or point me in the right direction on where to find the missing clearance
would be greatly appreciated. Thanks!
paulo57509


.- well this is what i do so here goes are you sure you input drum and rev drum are
seated all the way down ? i have a tool that will let me check the drum depth after
they are installed and them i check it to the pump
bp042665



.- I'm pretty sure the input and reverse drums are seated all the way down. Installed, I
laid a straightedge across the pump mounting flange and the rev drum is a good 1/8"
below the straightedge.


paulo57509



.- Well if you got a 1/8 that is good clearance you should be able to install pump and
check end play
bp042665


.- Just to close the loop on this:

I contacted the rebuilder that put my rebuild kit together and he told me that checking
end play without a selective washer (as I had done) will not yield any valid info.

He recommended installing a No. 67 (0.076" - thinnest selective washer available) and
re-check. He also told me that anywhere between 0.004" - 0.030" of end play is
acceptable.

I now have 0.027" of end play with the No. 67 washer.

Thanks to all here that contributed their comments and help.
paulo57509