Ok, so I tried searching this but did not find an answer.

I was looking to purchase a rebuild kit for a 4L60e transmission. I see there is a kit for 1998-2003 years and a kit for 2004+ years.

My car is a 2004 but it was build in 2003, so which kit do I need? Is there an easy way to tell the difference between 2003 and 2004 transmissions? IE prior to removal.

BIG QUESTION:

What is the difference between the two kits?

 

Perhaps one of the pro builders can tell you the difference, but it will be incredibly small and insignificant.
I strongly suggest everyone using this forum always use (or ask their stock builder to use) a 4L65E rebuild kit. The only different is that it has 7 frictions for the 3/4 clutch instead of 6. Sure it cost $10 more, but that 3/4 clutch is the most common failure reported here. So get a 2004 4L65E kit.

Also add the Sonnax 4l60-LB1 boost valve ($30). A new separator plate is also highly recommended - get the Transgo 46-PLT-96 ($20) and drill it according to its directions for a V8. You might want to drill the 3rd feed hole (also called 2-3 shift hole) a bit bigger to .093.

We have lots of threads now on how to rebuild your own trans and the success rate is going up dramatically. Here are a few recent/current ones:

https://ls1tech.com/forums/automatic...60e-build.html

https://ls1tech.com/forums/automatic...arts-list.html

Good luck.

 

How about the Torlon ***** I keep reading about. Are they a better, more reliable substitute for the steel ***** in the 4L60E?

 

They will not damage the separator plate like a steel ***** will

 

While the Torlon ***** are better, a new separator plate will last 100,000 miles even with the steel *****. Torlon ***** are only a few dollars.
As I understand Ford uses Torlon ***** extensively.

 

Starting in late '04, The Pump O-ring was eliminated & Replaced with a "Press-In" Metal clad seal, Most '04 models used the O-ring, If your trans was built in '03....Get the earlier kit.

 

Thanks guys. I'll go with the earlier design then.

 

Thank you for the correction and update. I keep forgetting that some of the later pre-ISS pumps have the seal pressed into the case.

You should be able to find a 2003 4L65E rebuild kit with the better 7 friction 3/4 clutch. If you have to get a 2004+ kit, any local trans shop should have spares of the pump o-ring. Or PM me your address and I will send you one.

 

Thanks for the clarification on the difference between the 2 kits.

 

you will also find in the late model kits they will not have lip seals for the input pistons in the kits and will have valve body gaskets for 200-2004 and 2005 and up