Rebuilding a 4T65E-HD - Part 6 reference material
 

Moving on to

Valve Body Reassembly:

Removed the separator plate gaskets (wetting them thoroughly with ATF helped them come off relatively easily), then sprayed well with brake cleaner and hung to dry:
https://www.gmforum.com/howto/ValveB...epplate001.jpg
https://www.gmforum.com/howto/ValveB...epplate002.jpg

There is an FSM test where you place the checkballs (10 in total) onto their little chamfered holes in the separator plate and see if light shines through from the bottom; all passed OK; will reuse with gaskets supplied in Master kit. Had the test failed, GM now replaces the gasket / plate / gasket with a plate with gaskets pre-bonded to both sides...undoubtedly to ease assembly. For 97-03 the p/n is 24217552; for 04+ is 24224544.

Sonnax boost valve and sleeve fix p/n 84754-30K:
https://www.gmforum.com/howto/ValveB...breassy003.jpg

Next to original boost valve and sleeve:
https://www.gmforum.com/howto/ValveB...breassy005.jpg

The Sonnax part's valves are much tighter in the new sleeve than the worn old parts. I think this will have been worth doing.

New Borg Warner 97-02 specific PCS solenoid, p/n 50123 (I have read that this solenoid is less prone to failure than the OEM Delphi):
https://www.gmforum.com/howto/ValveB...breassy001.jpg

PCS solenoid installed OK.

Sonnax TCC relief valve fix p/n 84754-43K:
https://www.gmforum.com/howto/ValveB...breassy004.jpg

Next to the original worn part:
https://www.gmforum.com/howto/ValveB...breassy006.jpg

This valve has a scarf-cut teflon seal (and an extra in case you mess up) that requires sizing. The seal is easy to install, but the sizing instructions that came with it were hard to understand, so I improvised with a layer of paper followed by 5 or 6 tight wraps with electrical tape, and let sit for 30 minutes:
https://www.gmforum.com/howto/ValveB...breassy008.jpg

This allowed me to install into the bore with no trouble using some tranny goo for lube:
https://www.gmforum.com/howto/ValveB...breassy007.jpg

After install, I held the valve with a screwdriver to compress the spring such that the seal was in place in it's bore (now I see what the temporary clips were for :) ):
https://www.gmforum.com/howto/ValveB...breassy009.jpg

After 10 minutes, the teflon seal was nice and tight, and I could install the new GM TCC / PWM solenoid p/n 24227747 (not year specific):
https://www.gmforum.com/howto/ValveB...breassy002.jpg

Now awaiting shift solenoids and a new TCC apply valve bore end plug from GMPD. Otherwise, all other valves in valve body completed.