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OVERHAUL – 4L60-E Fig. 16: Exploded View Of 4L60-E Transmission Internal
Components GENERAL MOTORS CORP.
1995 Chevrolet Chevy Van G20

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Remove or Disconnect (Figures 5 through 10 and Figure 20) 1. Battery ground cable. 2. Coolant recovery tank. 3. Heater core hoses (140 and 141) (figures 6, 7, 8 and 20). ^ Place a clean pan under the vehicle to catch any coolant spillage. ^ Plug the hoses. ^ Allow coolant in the core to drain into the pan. 4. Heater distributor duct (134) (figure 9). ^ Remove the screws that hold the distributor duct to the distributor case and the distributor duct to the engine cover. 5. Engine housing cover. Refer to Access Cover, Engine. See: Body and Frame 6. Instrument panel. See: Instrument Panel, Gauges and Warning Indicators 7. Lower the steering column. Refer to Steering Column. See: Steering and Suspension/Steering ^ Raise and support the right side of the instrument panel. 8. Defroster duct (130) to distributor case (124) attaching screws. 9. Distributor to heater case screws. 10. Temperature door cable (145) (figure 10). ^ Fold the cable back for access. 11. Heater case (124) and core (122). ^ Three nuts at the engine compartment side of the distributor case and one screw on the passenger side. ^ Tilt the case assembly rearward at the top while lifting up until the core tubes clear the dash openings. 12. Core retaining straps (123). 13. Core (122). Install or Connect (Figures 5 through 10 and Figure 20) 1. Core (122) to the heater case (124). ^ Apply a bead of permagum sealer between the core and the case. 2. Core retaining straps (123). 3. Heater case (124) to the vehcle. ^ Apply a bead of permagum sealer between the heater case and the opening in the vehicle. ^ Tilt the case until the core tubes clear the cowl opening. 4. 5. 6. 7. 8. 9. Temperature cable (145) to the heater case (124). Distributor duct (134) to the heater case (124). Defroster duct (130) to the heater case (124). Instrument panel. Steering column. Engine housing cover.

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1. 2. Disconnect battery ground cable. On models with mechanical speedometers, reach up under instrument panel and disconnect speedometer cable by pulling cable while pressing tang on rear of speedometer head. On models with mechanical clocks, remove clock set stem and knob. On all models, remove screws attaching instrument cluster bezel to instrument panel, then the bezel. Remove two lower cluster attaching screws, Fig. 15. Pulling top of cluster away from instrument panel, lift out bottom of cluster. Disconnect instrument panel harness connector from printed circuit and remove cluster. Disconnect headlamp and wiper/washer switches. Remove lower extension assembly, engine cover, air cleaner cover and element, Fig. 16. Remove radio control knobs and retaining nuts, Fig. 17. Remove radio rear mounting bracket, then push radio forward in vehicle and lower assembly. Disconnect antenna and electrical connectors, then remove radio. Remove steering column brace bolts and lower column. Remove heater and A/C control attaching screws, then disconnect A/C, temperature and defroster cables. Mark cables for assembly reference. Remove instrument panel attaching bolts and nuts, then disconnect any remaining electrical connectors and remove panel, Fig. 18. Reverse procedure to install. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

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AXLE SHAFTS – FRONT 1991-92 DRIVE AXLES FWD Axle Shafts Axle shafts transfer power from transaxle to drive wheels. Axle shafts consist of a shaft and flexible Constant Velocity (CV) joint at each end. See Fig. 1 . Inner CV joint is splined to transaxle. Outer CV joint is splined to hub assembly and secured by wheel bearing lock nut. Inner CV joint is a plunging tripod joint. The plunging action allows for axle shaft length change as suspension Inner and outer CV joints are enclosed by a CV joint boot. The boot maintains lubrication in the joint and prevents contamination of CV lubricant. Boots must be replaced when leakage or cracks are present. The inner CV joint can be repaired without replacing assembly. The outer CV joint must be replaced as an assembly.

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1. Disconnect the spark plug wire at each spark plug. ^ Twist the boots 1/2 turn before removing the boots. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wire from each spark plug. 2. Disconnect the spark plug wire from the distributor. ^ Twist each spark plug boot 1/2 turn. ^ Pull only on the boot or use a tool designed for this purpose in order to remove the wires from the distributor. INSTALLATION PROCEDURE NOTE: If the boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. Ensure that the boots have been properly assembled by pushing sideways on the installed boots. Failure to properly seat the terminal onto the spark plug will lead to wire core erosion and result in an engine misfire or crossfire condition, and possible internal damage to the engine. 1. Install the spark plug wires at the distributor. 2. Install the spark plug wire to each spark plug. 3. Inspect the wires for proper installation: 3.1. Push sideways on each boot in order to inspect the seating. 3.2. Reinstall any loose boot. 3.3. Wire routings must be kept intact during service and followed exactly when wires have been disconnected or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to the ground. 3.4. Any time the spark plug wires or boots are installed on the spark plugs, new dielectric grease needs to be applied inside the boot.