Thread: 4T65E rebuild questions

First post here - so hello all!

I'm rebuilding a 4T65EV/GT transmission in a Volvo S80 (MY2000) and was looking for some assistance with adjusting the clearances for the input clutch pack - I've sorted 2nd and 3rd (both at .050") but the input clutch pack is way off though and adding an extra steel removes all clearance - should I be concerned at the excess clearance? I could remove the clutch material off an old clutch plate and put that in like I did with 3rd...

Also, is it worthwhile increasing the 2nd / 3rd clutch feed orifices in the spacer plate (to say .090”?). I have the Transgo shift kit fitted but may mod the engine later (up to about 320bhp/320lbft).

Finally, I can't stretch to a new torque converter, so I wanted to flush out the one I have and get it as clean as possible. I saw a 'trick' on a US Horsepower/Muscle Car TV program where the guy drilled a small hole on the side the converter to drain the old fluid out and then put in a solid pop rivet to fill the hole - do you guys have any other suggestions? I've put in clean fluid and left it to drain upside down but it's a bit painful...

Cheers,

Chris

Thank you both for the suggestions and info - that's great! I'll think about the spacer plate hole sizes and see if the local transmission place can flush the torque converter.

I've come up with a way to stretch/shrink the teflon seals using PVC tubing which I've documented - but can't upload the PDF. The file is down to 875Kb but its exceeded my 142.3kb limit (funnily enough!) - is there a way I can get it uploaded?

Cheers,

Chris