4x4Wire's TrailTalk Forums: Gen2 maint... 4L30E

Well, lets see... I was quite productive Saturday.

Determined my EGR/CEL is most likely attributed to the 1-2" hole in the passenger side exhaust tube at the flange.

Unfortunately, I cant weld, and my Uncle who helped me, did not feel up to the challenge, a trip to midas for the re-weld is in order...

Found that the speedometer issue (not working) is most likely the VSS (Vehicle Speed Sensor), mounted on the transfer case passenger side output end. Best price on that one right yet is $175!

The main topic here... 4L30-E. Yes, the service manual does not REQUIRE the DexronIII to be changed.
However under te following extreme conditions, it SHOULD be:
Towing
Short Trips
Dusty Roads
Rough Roads

Hmm... I meet 3 of the 4 and @ 85k, so its time to change the filter, I have been doings flushes once a year.

So we get down there, look at it and determine what to do.
* Support drivetrain on the t-case skid plate with jack.
* Unbolt twisted, bent t-case/tranny crossmember.
* Remove brake/fuel line heat shield protecting said lines from the crossmember.
* Unbolt tranny support from crossmember and move crossmember out of the way.
* Remove tranny support from the tranny.
* Drain flid from tranny pan (2 plugs, one low, one high[allen head]).
* Once fluid has drained, unbolt the pan from the tranny and set aside.
* Unbolt filter from the tranny and discard.
* Remove gasket material left on the tranny and pan.
* Clean gasket mounting etc with a solvent on tranny and pan.
* Remove magnet from bottom of pan and clean all metal dust remnants from magnet, and wipe out pan after all fluid has been drained.

[rant on]Since some BRAINIAC at GM/Isuzu designed the 4L30E WITHOUT a dipstick or any other way to fill the fluid, you get to take a bath in Mercron, no two ways around it... :mad: Remember the allen head plug I referenced, well that is the overflow aka FILL plug too!!! So, since the overflow hole parallel to the ground, how do you suppose you place fluid vertically into a pan that holds the fluid, maybe 3" below that hole? WTF, some people shouldnt live, or breed as the case might be.[/rant]

* Install new filter on the tranny, round hole down.
* Fill up the pan with 6-7 pints of fluid (nearly to the overflow line.
* With two people, lift up full pan to the tranny, and stick 2 bolts in opposing corner with each person (all 4 corners are bolted)
* Complete the installation of the tranny pan, and reverse process for the crossmember, support, and jack.

Got the fluid in the diffs, tcase, engine, tranny, filters (air, gas, oil, tranny) changed out this weekend and discovered yet something else...

My lower trailing links are bent, SEVERELY on the drivers side, enough to make the axle sit ~0.5-0.75" more forward on the left side than the right, making a washing machine type sound. Found a source for $25/link so o worries there.

Found the source of my drivetrain clunk when changing into or out of drive/reverse. The transfercase output. It partially engages, then gets positive engagement through ~1/8 turn and significant clunk. The No Slip could be accentuating this trait, IMHO but not wholely responsible.

Does anyone with the TeraLows in a GEN2/auto have this issue? I am considering the possibility of missalignment, missing synchro, or something similar, any thoughts? I am going to be calling the shop that did the install last year and checking into it. I first noticed this ~ 6 months ago, have driven the Amigo maybe 5-6 times since, and think that within a year I shouldnt be havin that kind of issue.

Thanks for the assist,
K