INTENSE Street/Strip Shift Pak for 4T65E and 4T65E-HD Transaxles

SAC 9.6.05

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Applications: 1998-current Grand Prix GT 1998-current Monte Carlo 1998-current other applications using the 4T65E (non -HD) transaxle 1997-current Grand Prix GTP 1997-current Regal GS 1997-current Bonneville SSEi 1997-current other applications using the 4T65E-HD transaxle Note: this kit will NOT fit 4T60E transaxles

Figure 1- The INTENSE Street/Strip Shift Pak comes complete with everything you need!

The INTENSE Street/Strip Shift Pak is designed to give you crisp shifts under light to medium throttle positions, and very firm shifts at wide-open throttle. It is not designed to rip your dashboard out, break your input shaft or destroy your transaxle drive chain (please see disclaimer at the end of these installation instructions). Installation should average one to two hours depending on your skill level. No special tools are required other than an inch-pound torque wrench.

The INTENSE Street/Strip Shift Pak is installed by removing the transaxle pan, then the accumulator cover. The accumulator housing contains the 1-2 and 2-3 pistons that control the rate at which fluid pressure gets applied to the clutch packs during upshifts and downshifts. Our kit contains custom springs and spacers to create the ideal shifts for a mix of street and strip use. Shorter shift cycle times mean less time when the PCM retards ignition timing during each shift to protect the transaxle. Shortening the shift times serves to increase clutch life, due to less slippage between gears. Less slippage equates to less heat, and less heat can extend overall transaxle life. There are two basic settings, depending on whether you have a 245 mm. (stock in 4T65E transaxles) or 258 mm. (stock in 4T65E-HD transaxles) torque converter. This kit is by far the most comprehensive shift modifier on the market for our transaxles. Every kit includes: 5 custom accumulator piston springs 3 custom flat spacers 8 custom cylindrical spacers sandpaper to smooth accumulator gasket surface for improved mating new accumulator gasket abrasive pad to scuff accumulator bores for increased oil on bore walls 2 new piston seals new transaxle filter new transaxle filter seal transmission assembly lubricant extremely detailed installation instructions with full color images explaining how to inspect your transaxle pan contents, and properly prepare the accumulator cover, accumulator pistons and piston pins

Installation Instructions: 1) On level ground, raise and support vehicle by the frame rails under the front floor pan. The frame rails are directly behind the rear cradle bolts. Use good quality jack stands to support the vehicle. 2) Allow vehicle to sit for approximately a half hour to drain fluid toward the transaxle pan and allow fluid to cool down a bit. 3) Place a large drain pan under vehicle and remove the transaxle pan by removing the bolts on the passenger side one at a time until fluid begins to drain. Remove remaining bolts slowly until pan is close to empty. Pan can now be removed. 4) Evaluate debris in pan to determine whether or not a shift kit is a wise thing to do. Metallic sludge on the magnet is normal. Slivers or fragments are not. The inside of the transaxle pan should not be discolored with sediment. Staining or hazing of the inside of the pan is indicative of clutch or band failure. Figures 2 and 3 are normal transaxle pan contents. Figures 4 and 5 are abnormal pan contents. If any of these abnormal conditions is present, please do not proceed with the shift kit installation. We recommend that you consult a transaxle expert, or send an email to Sales@INTENSE-Racing.com for advice.

Figure 2 normal transaxle pan contents

Figure 3 normal transaxle pan contents

Figure 4 abnormal transaxle pan contents

Figure 5 abnormal transaxle pan contents

5) With the pan removed, you can now remove the filter. Be sure to have the drain pan positioned to catch fluid from filter removal. 6) Remove shift accumulator assembly from transaxle by removing the necessary bolts. Remove accumulator tubes and differential oil tube. Differential oil tube can be removed by popping the retainer clip out, then coaxing the tube out. 7) With the accumulator assembly placed on a clean workbench, remove the remaining bolts and disassemble. Remove and discard the accumulator piston seals and accumulator cover gasket. Using aerosol brake cleaner, thoroughly clean all components. Be sure to remove all metal residue from the accumulator bores. Clean the rest of the accumulator and the differential oil tubes as well. 8) Inspect the accumulator cover for signs of damage. Figure 6 is an example of normal accumulator cover condition. If an accumulator piston has deformed the area indicated, then your accumulator cover must be replaced before reassembly. These can be purchased at any G.M. dealership, by asking for part number 24205584.

Figure 6 normal accumulator cover

9) Inspect the accumulator piston pins for excessive wear and/or damage. Both pins should be smooth and free of lips or recesses that would indicate the piston has been binding on the pin. Evidence of this warrants replacement of the piston(s) and piston pin(s) before reassembly. These can be purchased at any G.M. dealership, by asking for part numbers 24206857 (accumulator piston) and 24203979 (accumulator piston pin).

10) Prepare the accumulator bores by using the provided abrasive pad to scuff each bore. This procedure ensures longer seal life due to increased oil on the bore walls. Using one piece of the provided sandpaper, polish the piston pins to remove any small scratches. Use the other piece of sandpaper to smooth the flat gasket mating surfaces of the accumulator cover and housing. With these preparation steps complete, again THOROUGHLY clean all components with aerosol brake cleaner.

Figure 7 side view of accumulator

Figure 8 top view of accumulator

11) Install the provided new seals on the accumulator pistons. Thoroughly lubricate the bores and seals with the lubricant provided. 12) Determine what size torque converter you have using the following chart: 1997-current Grand Prix GTP - stock torque converter is 258 mm 1997-current Regal GS - stock torque converter is 258 mm 1997-current Bonneville SSEi - stock torque converter is 258 mm 1997-current other applications using the 4T65E-HD transaxle - stock torque converter is 258 mm All known aftermarket torque converters for these vehicles are 245 mm.

1998-current Grand Prix GT - stock torque converter is 245 mm. 1998-current Monte Carlo - stock torque converter is 245 mm 1998-current other applications using the 4T65E (non -HD) transaxle - stock torque converter is 245 mm All known aftermarket torque converters for these vehicles are 245 mm.

13) Figure 9 is the recommended assembly sequence for all applications with a 258 mm. torque converter. 2-3 is assembled as follows: pin, #3 spacer, #1 spacer, white spring, red spring, plain spring, accumulator piston/seal assembly, one flat spring spacer, #2 spacer, 2-3 shift spring (large coils). 1-2 is assembled as follows: pin, white spring, plain spring, #3 spacer, #1 spacer, accumulator piston/seal assembly, #2 spacer, 1-2 shift spring (small coils). Hint: assembly is easier if you use the provided assembly lubricant to glue the plain spring into the piston before installation. Note: the four different sizes of cylindrical spacers are numbered 1 through 4, with 1 being the shortest and 4 being the longest.

Figure 9 recommended assembly sequence for all 258 mm. torque converter applications

14) Figure 10 is the recommended assembly sequence for all applications with a 245 mm. torque converter. 2-3 is assembled as follows: pin, #3 spacer, #1 spacer, white spring, red spring, plain spring, accumulator piston/seal assembly, two flat spring spacers, #4 spacer, 2-3 shift spring (large coils). 1-2 is assembled as follows: pin, #3 spacer, #1 spacer, white spring, plain spring, accumulator piston/seal assembly, one flat spring spacer, #4 spacer, 1-2 shift spring (small coils). Hint: assembly is easier if you use the provided assembly lubricant to glue the plain spring into the piston before installation. Note: the four different sizes of cylindrical spacers are numbered 1 through 4, with 1 being the shortest and 4 being the longest.

Figure 10 recommended assembly sequence for all 245 mm. torque converter applications

15) With your shift kit assembled in the bores, install the gasket and cover and HAND TIGHTEN the bolts shown in Figure 11. Then torque them slowly and carefully torque these same bolts to 106 inch-pounds (NOT foot-pounds!).

Figure 11 reassembled accumulator assembly

16) With the assembly complete, lubricate both ends of all three tubes with the lubricant provided, and reinstall the accumulator assembly into the transaxle using the remaining bolts. It may be necessary to wiggle the accumulator a little bit in order to properly align the bolt holes and tubes simultaneously. HAND TIGHTEN the bolts shown in Figure 12. Then torque them slowly and carefully torque these same bolts to 106 inch-pounds (NOT foot-pounds!).

Figure 12 bolts that fasten accumulator assembly to transaxle

17) Install new filter and filter seal, and reinstall cleaned transaxle pan. Pan gasket can be reused. Torque all bolts to 120 inch-pounds (NOT foot-pounds!). 18) Lower the vehicle and ad six quarts of transaxle fluid initially. Allow the car to run until completely warmed up. With the emergency brake engaged, and your foot firmly on the brake pedal, run the transaxle through all the gears several times. Then check the transaxle fluid level with the engine running and add additional fluid as necessary.

19) Once fluid has reached the proper level, go ahead and drive the car. The shifts should feel crisp under light to medium throttle positions, and very firm at full throttle. Remember, the object of this shift kit is to decrease shift times, and not damage the transaxle by slamming into gears. 20) Enjoy!

Disclaimer: Transaxle components fail especially in cars modified for increased power outputs. Transaxle failures occur in completely stock transaxles and ones with shift kits too. Your purchase and/or installation of this product constitutes your acceptance of any and all liability with regard to this product. INTENSE Enterprises, Inc. will not be held liable for any transaxle or other damage that occurs due to the installation, misinstallation or use of this product.