1996 2500 4l60e no second gear???

I just found this site seems like there is a lot of knowledgable people on here from what I have read so far. Hopefully someone can help me with my problem.
I have a 96 light duty 2500 with the 4l60e trans I bought it 6 month ago for a good deal. Everything works great excepty that 2nd gear does not work it starts out in 1st the rpms come up and then shifts to 3rd if you make it down shift it just revs and wont accel have to drive it very carefully. All I have is 1st, 3rd, 4th do I need to have it rebuilt or is there an electrical problem???

Get it on a good transmission /engine capable scanner and check for codes.
Post back code no.

Any check engine lights?
What is the mileage and fluid level and condition?
Have you check the transmission filter?

Get it on a good transmission /engine capable scanner and check for codes.
Post back code no.

Any check engine lights?
What is the mileage and fluid level and condition?
Have you check the transmission filter?

Soon as I started having the problem I changed the fluid and filter the fluid is at the right level I do have a check engine light that the code tells me is for a heated o2 sensor that I still have to replace.
If there is an electronic problem with the trans will there always be a check engine light?

Not always.
Check for transmission codes with a engione /transmission capable scanner.
MT

Not always.
Check for transmission codes with a engine /transmission capable scanner.
MT
I finally took the van to a trans shop they did a complete inspection with a scanner they did not find any trans codes they dropped the pan, the fluid looked a little burnt. They suggest a whole rebuild.
My question now is with second gear and fourth gear sharing the same clutches why does fourth gear work and second gear does not, it seems to me that it doesn't even try to shift to second just first then right to third. When I manually shift to second it does feel like it slips.

Any metal or extra clutch material in the pan?
A good scanner and a good transmission tech should be able to test it out and find the cause of the problem.
Just a code check sometimes is not enought .
If only no 2 nd gear and no slippage it may be electrical.
They need to get in there and read out the transmission data.
Many transmission chain stores are rebuild happie.
I would suggest you have a good repair shop or dealer check it out before a transmission rebuild.
Good Luck
MT

The fluid looked a little brownish in the bottom of the pan but no metal chunks.
I can get a complete rebuild kit for 150$, with a good manual is it possible to rebuild the trans myself? I have been working on cars for along time and consider myself a pretty good mechanic but I have never attempted a trans before.

Yes, you can:

4L60-E Repairs (http://mysite.verizon.net/strey/files/4L60ERepairs.html)

The fluid looked a little brownish in the bottom of the pan but no metal chunks.
I can get a complete rebuild kit for 150$, with a good manual is it possible to rebuild the trans myself? I have been working on cars for along time and consider myself a pretty good mechanic but I have never attempted a trans before.

I would still make sure you need a rebuild.

Yes good repair info is the first step.
ATSG and ATRA make good repair hand books.
The link posted is good.
The kit is only a small part of a rebuild.
A lot of hard parts need checked and replaced for a good rebuilt.
Also special tools.

Take it down to bare metal and clean and clean it good enought to eat off of it and then inspect everything that moves in it including case and converter.
Most parts for a good rebuild will run into the 750$ or more figure.
And do not forget a good quality rebuilt converter and a cooler flush.

MT-2500, I can't thank you enough for all the info I am going to work on it tomorrow and will post back with what I find out. That link will help for sure but I still might have some questions. THANK YOU!!!

Okay I got as much out of it as I could now I am left with 1st gear and reverse after getting stuck in the snow and having to beat on it a little bit I am going to put it on the hoist tomorrow and pull the trans out. After looking at the repair guide that blue bowtie gave me the link to I think I can handle it just a little scared never tore into a trans before.

Is there anything that I should really look for or know about before I begin and is there any special tools that I need other than snap ring pliers and torque wrench?

If first time just take your time and get a good book on it.
Take it down to bare metal and clean it up good or so you can eat off of it.
Transmission parts places have hand books put out by ATSG and ATRA that are real good on repair and all updates.

Some special tools are needed.
The small pump starter shaft seals and pump stub have solid teflon seals that need a special seal install or to put them on.
Clutch piston compressers will also be needed.
To save buying them for a one time job a transmission shop may be the best to get them installed for you.

I always replace the converter with a good quality rebuilt and flush the transmission coooler out good.
Good Luck
MT

I have removed my trans and have noticed that the bell housing does not unbolt from the trans like in the link that blue bowtie gave me. Is it the same trans just different case with the van being two wheel drive and the trans in the link being 4 wheel drive?

Yes and no.
Basic parts are the same But.
The one piece case transmission on the van with a V8 will have a few more clutches in the clutch packs.
Blue Bowtie's link is good basic info on it.
But
I would sugest you get the ATSG or ATRA hand book/books for your year van and go threw them on updates and changes and clutch pack stackup/setups.
Also the hand books show the special tools you will need.
Some of the seal installers are a have to have.
Lot of pump and stater plastic rings are now one piece and need the tools to install.
For a one time rebuild some transmission shops will install the one piece seals for you to save 200-300 or more dollars in special tools.
Most transmission parts places have them and you can get them when you get your parts.
And remember to get a good quality rebuilt converter and flush the rad and or any external transmission coolers out good.
Good luck
MT

I have taken the trans apart and am surprised on how easy it is going thought there was allot more to it. Hopefully I am doing it right. The only real problem is that I broke every internal wire harness clip, I was being as careful as I could be and it didn't help they where so brittle.

My question is that the reverse input drum looks a little blued and the band is junk, do I have to get a new drum or is there away to clean the old one up?

I have taken the trans apart and am surprised on how easy it is going thought there was allot more to it. Hopefully I am doing it right. The only real problem is that I broke every internal wire harness clip, I was being as careful as I could be and it didn't help they where so brittle.

My question is that the reverse input drum looks a little blued and the band is junk, do I have to get a new drum or is there away to clean the old one up?

That is where you need a good transmission hand book.
The hand book says to put a straight edge across it and if dished out or warped replace it.
Also check where steel clutch plates notch into it.
I have found a lot of them the clutch plate notches are about cut threw it.

Another thing to check is the the reverse input piston for dishing

Get the transmission hand book and go threw everything in it.

No problems on broken clips.
The wiring may be hard and burnt to.
You can buy a new set of wiring.
Good luck
MT

I am going tomorrow morning to get the parts I need and hopefully have it back together and on the road by tomorrow evening.

I am going tomorrow morning to get the parts I need and hopefully have it back together and on the road by tomorrow evening.

Take you time and go threw everything in there.
Good luck and let us know how it goes.
MT

I took my time and went thru every part put it all back together and installed it in the van with no luck. It doesn't drive at all like the pump is not pumping or something. Its not making any bad noises or anything.
The only thing I was not sure of when I put it back together is the two valve body gaskets I followed the instructions the first gasket went on just like it should then the plate and then when I came to the gasket between the valve body and the plate nothing seemed to line up, the gasket didn't even seem big enough and the bolt holes did not line up, I probably should have waited to see if it was the right gasket before installing but I figured that with buying the kit I would have received the right gasket.

Any ideas on what could have gone wrong?
I am going to drop the pan in the morning and see what is up.
How can I tell if the pump is pumping?

I took my time and went thru every part put it all back together and installed it in the van with no luck. It doesn't drive at all like the pump is not pumping or something. Its not making any bad noises or anything.
The only thing I was not sure of when I put it back together is the two valve body gaskets I followed the instructions the first gasket went on just like it should then the plate and then when I came to the gasket between the valve body and the plate nothing seemed to line up, the gasket didn't even seem big enough and the bolt holes did not line up, I probably should have waited to see if it was the right gasket before installing but I figured that with buying the kit I would have received the right gasket.

Any ideas on what could have gone wrong?
I am going to drop the pan in the morning and see what is up.
How can I tell if the pump is pumping?


Oh MY
That does not sound good.
You may have the wrong gasket set.

To see if the pump is pumping remove the cooler lines from rad and hose them into a 5 galllon bucket.
How many qts of fluid did you put in it?
With transmission fluid full it should pump fluid out of the pressure line into the bucket.
Also to check for transmission pressure there should be a pressure test plug on it.

On the gasket you may have the wrong one.
A good quality kit comes with several valve body gaskets and the instructions on which one to use for different years..
What brand or kind of kit did you get?
Was the kit for that year of transmission?
Did you get the ATRA hand book on it?
Look threw your book and see if it gives the different valve body gaskets and valve body check balls and spacer plate setups.

If it is full of fluid 10-12 qts and pumping fluid I would drop the valve body and check for the right gaskets.

I did get the ATSG book and that did help a lot for the internals of the trans I took my time on the inside so I really don't think there is a problem in there.
I put 10qts in it I am going to check on the pressure right now and do what you suggested. They only gave me to gaskets for the valve body and they did not match, in looking at the pictures in the book I have it seems to me that they should have matched up. I am hoping that this is my problem and I can find the gaskets at the auto parts.

If the parts place does not have a good applacation on the gaskets it your dealer with the vin no or if you have a transmission shop near they may be able to help with the gaskets.
Good luck and let us know how it goes.
MT

I went to the dealer today and got the right gaskets put them in and now I have first, second, and third, but only if I manually shift it I don't get anything in drive and it feels like it could be slipping when in gear.
Is there a chance my pump might not be making enough pressure?

I think I should have just coughed up the money and had a pro do it but all in all it was a learning experience. I just don't understand what went wrong I did everything just by the book.

I went to the dealer today and got the right gaskets put them in and now I have first, second, and third, but only if I manually shift it I don't get anything in drive and it feels like it could be slipping when in gear.
Is there a chance my pump might not be making enough pressure?

I think I should have just coughed up the money and had a pro do it but all in all it was a learning experience. I just don't understand what went wrong I did everything just by the book.

Doing it yourself is a good way to learm.
The old school of hard knock is the way I learned.
There should be a pressure tap where you can check the pump and transmission pressure.
But where the transmission shifting is computer controlled I would get it on a transmission capable sanner and check things out.
A good scanner will give you a lot of info on it and sometimes codes.
Let us know how it goes.
Mt

Hi;

New member here. I have the exact same problem. 93 c1500 runs great in 1st gear, no 2nd gear -- but let off the gas around 25-30mph and she goes right into 3rd. Runs great down the highway 75-85mph. 269,000 miles.

Get it on a good transmission /engine capable scanner and check for codes.

Not sure what scanner to get or where to purchase. Would appreciate recommendations.

TIA.

Charles...

Hi;

New member here. I have the exact same problem. 93 c1500 runs great in 1st gear, no 2nd gear -- but let off the gas around 25-30mph and she goes right into 3rd. Runs great down the highway 75-85mph. 269,000 miles.



Not sure what scanner to get or where to purchase. Would appreciate recommendations.

TIA.

Charles...

Welcome to AF
Best to start a new threador new post with your problem and some on will help you.

The transmission/engine capable scanners are high dollar idems.
Can run up to 4-5 K US$ for a good one.
For a one time check best to find a good repair shop.
MT