1996 2500 4l60e no second gear???

[BHolm]

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???

[MT-2500]

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?

[BHolm]

Originally Posted by MT-2500

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?

[MT-2500]

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

[BHolm]

Originally Posted by MT-2500

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.

[MT-2500]

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

[BHolm]

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.

[Blue Bowtie]

Yes, you can:

4L60-E Repairs

[MT-2500]

Originally Posted by BHolm

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.

[BHolm]

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!!!

[BHolm]

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?

[MT-2500]

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

[BHolm]

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?

[MT-2500]

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

[BHolm]

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?