96 - 05 Light Duty Trucks and Utilities with 4L80E Output Carrier Thrust Washer Changes - kw automatic bearing MT1 overhaul noise part repair transmission shift slip washer

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in the PI.

Prior to MY 2002 the output carrier assembly (661) was manufactured with four holes to receive the tabs on the output carrier thrust washer (659). The production P/N 8624077 was a steel 4 tab thrust washer (659), The service P/N 8626372, which is a steel 4 tab thrust washer, was used to service the output carrier thrust washer (659) and was also the same part for servicing the output shaft thrust washer (673). Since the MY 2002 the output carrier assembly (661) was manufactured with two holes to receive the tabs on the output carrier thrust washer (659). At that time it was also decided that the same carrier assembly used for the prior model years would also use the two hole design. The output carrier thrust washer (659) was also changed to a 2 tab plastic thrust washer P/N 24214809.

For service parts all of the output carrier assemblies (661) will now have the 2 hole design. This will require to use the output carrier thrust washer (659) P/N 24214809. If servicing the transmission and the output carrier assembly (661) has the 4 hole design the 2 tab plastic thrust washer P/N 24214809 will work. If the 24214809 thrust washer is not available the 8626372 thrust washer could be used by cutting off two of the tabs. The parts catalog is in the process of being updated to reflect these changes.

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Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

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