Stock(ish) rebuild

[BrandonHall10]

I recently aquired a used 4T65E-HD as a core. I wanted to do a slightly better than stock rebuild.


Here's what I know about the trans:
Came out of my brothers 2002 Regal GS
Car had 87,000 miles on it but,
Trans only had 42,000 (was replaced once already @45,000)
Trans was a GM remanufactured trans (I'm assuming. Due to the big "GM Parts" sticker on the side cover and 02XAB stencil.)
Before removal it was throwing P0742 (Torque converter clutch stuck on) and P0757 (Shift solonoid "B" stuck on)


The candidate:



The pan:



What I would like to do is rebuild and have ready to reinstal for when mine eventually goes, or for when my brothers goes again.


So here's my questions, based on what we know:
1.) With moderate mechanical knowledge, an ATSG manual (http://shop.tripleedgeperformance.co...l-TM-4T65E.htm), this forum,
and LOTS of time, is this something I can do myself? What problems should I expect?


2.) What parts should I order? I don't think this trans will ever see a turbo motor, but I also want it to be able to handle some decent power.
Possibly a combination of E85, 1:9RR's, 3.0 pulley, headers, a good tune, and maybe even an IC. Where should I spend some extra dough, and where can I save some dough?
Is my best bet the TEP Complete Kit? (http://shop.tripleedgeperformance.co...65E-CK9702.htm)
Or is that more than I would need?


3.) Do I need to crack this thing open before I even know what to order?


Sorry for the wall of text, but I wanted to give as much info as I could up front.


tl;dr
Need input on a DIY trans rebuild

[rileychris]

If it's any help there is a guy on ebay that sells a DVD that walks you through step by step what to check for for wear etc there is two versions of the DVD a stock rebuild and a what he calls high performance ... if your just looking for a tutorial it's very helpful imo. . But triple edge for parts is going to be your best bet he knows his stuff give em a call he will set you up with everything you need.

[ADrugDealer]

Surprised no one has replied yet...

Answers to questions:

1) Yes. I did it in my garage with an ATSG manual and the DVD listed above. I did get a few special tools listed in the video/ATSG.
Tools)
a) Input,Third,Second puller - A tool used to install/pull these together. Pulling not hard without, installing is a *****, you can use fishing line to do it but yeah... I'm one for the tool. $100-200 bucks
b) Lip Seal Installer - Used to install multiple lip seals. Will be used on some, and plastic baggies on others... (Baggies are used to cover area, slide seal down and into place
c) Clutch Spring compressor - http://www.amazon.com/OTC-7024-Autom...ing+compressor
d) Lots of plastic baggies/sharpie
e) other hand tools
f) If you plan on removing park ( you don't have to unless you clean the sun gear) you will need a loooonnnggg flat head screwdriver that you cut a notch into to stick behind the snap ring, turn (so it locks in the cut notch) and pull out.. reverse to install.

2) Master rebuild kit from TEP can go whatever stage you like. I did stage 2 but I am a Turbo Guy... You'll want a GXP hardened chain and a 300m input shaft... The rebuild kit if you go with a higher stage will have the sonax third and other "performance" options. Get the vale body/channel plate done by dave. Trust me. Much easier on you..and no one does it better than him. I also had him do third for me because I didn't wanna eff with it as it has lots of lip seals and I am lazy. Many people have successfully done it though.

3) No. Talk to Dave @ TEP. Hell get the right parts too you..

I can't stress this enough, if you tackle this HAVE LOTS OF BAGGIES TO STUFF PARTS IN AND A SHARPIE TO LABEL THEM. The ATSG has names for EVERY SINGLE part along with a number (seen in the big exploded views of the transmission). Write the name AND the number on the baggie, you will thank me later when you are sitting there going "These two bearings look identical, where do they go??!?!" and can look at the baggie and go oh 851 goes here and 342 goes here (Random numbers).

I did this, you can do. Not hard if you go slow and stay organized.

[16MustangVet]

send me your email I have a ATSG manual for the transmission step by step assembly and TQ specs are in it. Its in a pdf format I printed a copy put it in sleeves and in a binder. now greasy shop manual wont trash the pages lol = WIN!

[ADrugDealer]

did the same.

[BrandonHall10]

Wow. Thanks guys. This is the kind of feedback I was looking for!

I've been squirreling funds away for a trans, per the recommendations of countless people. When the time is right, I will shoot Dave an email. Sounds like he's a good guy, and pretty easy to work with. Can't wait to add "built trans" to my mods list!!

[DJNight2k]

He (Dave @ TEP) is one of the most helpful and knowledgeable people I have ever dealt with in the transmission industry. He has spent a LOT of time testing and building and modifying 4t65e transmissions. He is a very valuable resource. Sometimes takes a little while to get back to you via email, but always takes the time to give good, honest answers. He hooked me up with a 700r4 rebuild/upgrade for a trans I was doing for a friends offroad truck. Can't say enough good things about Dave.