Left sub frame has been dropped. All of the side cover bolts have been removed. The last lower right torx bolt head wanted to strip but by using a 24" and a 18" extension combined, I was able to lean my weight into the head while turning and popped it loose.

The tranny side cover engine mount bolts to the body frame with two nuts and a horizontal bolt. What size is the bolt head? A 14mm 12 point won't fit and a 15mm 12point socket just spins. Do I need a 15mm 6 point socket?

Neither, loosen the 18mm nut on the opposite end of the bolt in the engine bay. DUH!

2 of the 10mm head bolts holding the channel plate on rounded enough to prevent removal with a socket. Masking off the area around the bolts, using a 4" air grinder, the heads were ground enough to permit the bolts to be unscrewed. Off comes the plate.

Out slides the 4th gear clutch hub, splines on shaft end totally gone. Date on shaft:11/19/1999


Slide in the new hub shaft, wiggle it a little and it seats fully. I did not remove the differential or the output shaft.

Reassembly time.

PS Note how this thread actually has informative pics, not just repeated car body photos like most threads.

Side cover is back on. Only used new case cover gaskets & the square cut O-ring. The old O-ring was ok but since I had a new one I installed it. Did not use the new valve body gaskets since I didn't want to hassle with the body disassembly.

That'* a risky decision, IMO.

Yeah, after thinking about it, I decided to use the new valve plate gaskets. Popped things apart & put them in.

Tip: use petroleum jelly to hold the 4 check balls in place in the channel plate before installing the valve plate.

Need to have the rotors turned before putting the wheels back on.

One of the rotors didn't clean up, a new one was required. I also installed new ceramic pads.

Tranny works great!
Took 10 quarts to fill.

Out of pocket costs:
$16 for ATSG 4t65e service manual
$79 for clutch hubs shaft & gaskets plus shipping
14 for filter & pan gasket
25 for fluid
$134 total

Additional costs not associated with transmission
New set of front ceramic front brake pads, 1 new rotor and 1 turned rotor about $65

Knowledge gained, satisfaction of DIY plus confidence boost, Priceless!

PS Did not break any clips on the wiring harness, no major wear on the oil pump shaft. The only tool I had to buy was a 34mm socket for removing the axle nuts. I'll need that when the wheel bearings go. Hardware parts for engine support, $7.50 (the 2X4'* were a couple of used ones I had laying around.)

Glad to see everything worked out ok. Congrats on a job well done.

Thanks.
I owe you. It was your posts that gave me the confidence to go ahead & fix it myself.

I did the rebuild, now i think my car needs to go to a junk yard. The low gear forward band broke. I did the work in the car. Got the band replaced. Went ahead and replaced the other 2 while i was in there. I replaced all the clutch plates also. Now i don't have overdrive. And it kind of sounds like it'* whining now. I could use any help. I can't get another car now.