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You are going to have a hole in your transmission case around your differential. The cross pin that holds your spider gears has come loose from over spinning and made a window in your transmission trying to get out. Very common . Hope every thing works out for you.
Checking Oil Level
Oil Fill And Vent Cap – 4T40E Transaxle
This procedure has been updated by TSB # 63-71-06 dated March 1997.
Start engine and drive vehicle until the transaxle reaches operating temperature of 82-130°C (180-200°F) . This temperature is reached after about 24 km (15 miles) of driving.
NOTICE: Temperature will greatly affect transmission oil level. If the vehicle is not at normal operating temperature and the proper checking procedures are not followed, the result could be a false reading of the oil level indicator and an incorrect adjustment of the oil level.
Inaccurate oil level readings will result if the oil is checked immediately after the vehicle has been operated under certain conditions:•In high ambient temperature above 32°C (90°F).
•At sustained high speeds.
•In heavy city traffic during hot weather.
•As a towing vehicle.
•In commercial service (taxi or police use).If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to cool for thirty minutes. Then restart the vehicle and continue from step two.
The fluid level screw is intended to be used for diagnosing a transaxle fluid leak or resetting the transaxle fluid level after service that involves a loss of fluid.
Inspect
The fluid level should be checked when the transaxle is near Room temperature or at 40°C (104°F) .
CAUTION: Removal of the fluid level screw when the transaxle fluid is hot may cause injury. Use care to avoid contact of transaxle fluid to exhaust pipe.
The engine must be running when the transaxle fluid level screw is removed, or excessive fluid loss will occur. Since the actual fluid level is unknown, stand clear when removing the fluid level screw. Have a container ready to capture any lost fluid.
WARNING: Do not turn the engine off with the fluid level screw removed as you can be injured by hot transaxle fluid being expelled out of the fluid check hole.
1.Let vehicle idle for three to five minutes with accessories off.
2.Apply brake
3.Move shift lever through all gear ranges, pausing three seconds in each range.
4.Place shift lever in Park.Important: Vehicle must be kept level on the hoist.
5.Raise vehicle on hoist.
6.Place oil container under fluid level screw.
7.Remove the fluid with the engine running at idle.
8.Fluid level should be at the bottom of the fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to ADDING TRANSAXLE FLUID.
9.Install fluid level screw.Tighten 12 N.m (106 lb in)
10.Lower vehicle.
11.Shut off engine.Adding Transaxle Fluid:
With the engine running, add fluid at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole.
1.Install fluid level screw.
Tighten 12 N.m (106 lb in)
2.Lower vehicle.
Let us know what you find out. Also worth mentioning on these transmissions is the bottom pan is prone to getting hit and scraped and developing leaks in that area if you are losing fluid that is where I would look closely.
1.Let vehicle idle for three to five minutes with accessories off.
2.Apply brake
3.Move shift lever through all gear ranges, pausing three seconds in each range.
4.Place shift lever in Park.Important: Vehicle must be kept level on the hoist.
5.Raise vehicle on hoist.
6.Place oil container under fluid level screw.
7.Remove the fluid with the engine running at idle.
8.Fluid level should be at the bottom of the fluid check hole. Because the transaxle operates correctly over a range of fluid levels, fluid may or may not drain out of the fluid check hole when the fluid level screw is removed. If fluid drains through the fluid check hole, this transaxle may have been overfilled. When fluid stops draining, the fluid level is correct and the fluid level screw may be installed. If fluid does not drain through the fluid check hole, the transaxle fluid level may be low. Proceed to ADDING TRANSAXLE FLUID.
9.Install fluid level screw.Tighten 12 N.m (106 lb in)
10.Lower vehicle.
11.Shut off engine.Adding Transaxle Fluid:
With the engine running, add fluid at the vent cap location in half liter (1 pint) increments until fluid drains through the fluid check hole. Allow the fluid to finish draining through the fluid check hole.
1.Install fluid level screw.
Tighten 12 N.m (106 lb in)
2.Lower vehicle.
Probably going to be hard to figure out how much was removed at resurfacing. The most common amount i deal with is .040-.050 shims.Might try that amount and see how things work or get a new or known original thickness flywheel.
Sounds like they did not shim the flywheel to compensate for what was removed. It will work for a while until the clutch gets seated in and some ware occurs and the you have the symptoms you are describing.
Pretty low miles to have syncronizer issues. Wrong type fluid is the main cause of early failure of syncronizers. Do you know if they resurfaced the flywheel when they did the clutch job or replaced the flywheel? If it was resurfaced it may not of been shimmed or shimmed correctly. Let us know what you find out.
It is very common for the solenoid connector plate to fail. It contains the input and output speed sensors. Easy to change,just need a 30 torx bit and a 7mm socket. Also make sure to change out the harness to case connector with the updated one.
The transmission will have to come apart and have the output shaft changed. Now you have two options here, a bolt on yoke or slip yoke. Slip yoke sounds more like what you will be needing. Also need a tailhousing. Good luck,,keep us up to date on progress.
2004 Chevy Truck Avalanche 1500 4WD V8-5.3L VIN T
Vehicle » Technical Service Bulletins » All Technical Service Bulletins » A/T – 2-3 or 3-2 Shift Clunk Noise Information
•A/T – 2-3 or 3-2 Shift Clunk Noise Information
# 01-07-30-042H: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise – (Jan 14, 2014)
Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise
Models: 2014 and Prior GM Passenger Cars and Light Duty TrucksEquipped with 4L60-E, 4L65-E or 4L70-E Automatic
Transmission (RPOs M30, M32, M70)This bulletin has been revised to add the 2013-2014 model years. Please discard Corporate Bulletin Number 01-07-30-042G.
Important :
For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin Number 05-07-30-012.
Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift.
During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be more pronounced on a 4-wheel drive vehicle due to the additional tolerances in the transfer case.
This is a normal condition. No repairs should be attempted.
There are Two possible type transmissions in vehicle. 4R70W which if you look at trans pan will be square with 2 rear corners cut at angle. Other possibility would be the 5R110W which has a rectangle shape and if around 20″ in length. Find out what type you have and we will try to help you diagnose.
