truckdoug's "UGH A 4L60e" rebuild thread
 

i swore i'd never do it but I have a friend in need.

what things do you guys mod to make them live in mild 4wd applications?

No expert on the subject but my 05 Tahoe 4X4 has a 4L60 and when it comes time to rebuild I'll be taking that task on myself so I'd be looking for OEM replacement parts.

There was a great informative video on rebuilding the 4l60E on transmissionbench.com, I've attached a link to their web page.

https://transmissionbench.com/4L60Eparts.html

What type of Truck?
How heavy?
Engine/ Power?
Type of suspension?
Which Transfer-Case?
Which Diffs?
Tire Height?
Purpose?

-Avoid the early cases with an integrated Bell-housing (the 4-bolt tail-housing flange is weaker than the 6-bolt).
-Billet shafts maybe worth it, depending on weight and/ or power.
-Heat treated stator-support tube.
-Install a Sonnax wide-bushing in the front of the stator-support tube.
-10 Vane pump with "unbreakable rings".
-Try and keep the torque-converter size down as long as you do not have to raise stall-speed too high.
-Most of the TransGo HD2 is worth it... keep 2nd Accumulator tame and 2nd feed small.
-Do NOT use a GM separator-plate with bonded gaskets (the screens for the solenoids are too restrictive).
-Alto Wide Carbonite Band 0.040" clearance with Corvette Servo.
-4L79 Input-Drum.
-Install a PTFE pump-bushing in the Reverse Input-Drum instead of the original smaller diameter bushing.
-Install 2 stock size Sun-Gear bushing in the rear Sun-gear, instead of the Sonnax wide bushing.
-Sonnax Reaction-shaft.
-New forward Sprag with perfect races.
-Raybestos GPZ 3-4 frictions with Kolene steels 0.020" - 0.025" clearance.
-Allomatic HE (Carbon-Graphite) Forward frictions (if used for heavy towing).
-Use early THM700-R4 Reverse-Input frictions.
-Do NOT reduce the bleed size in the Reverse-Input clutch apply-piston as the TransGo instructions say... do NOT follow the TransGo instructions here.
-Adjust Reverse-Input clearance (Or selective backing-plate) for 2 waved-steels from an early THM700-R4 (do NOT use the Belleville steel).
-Adjust Low-Reverse clearance (Or selective backing-plate) for 2 waved-steels.
-Be very particular with bushing fitment and thrust end-play.
-Sonnax 2-3 shift-valve, and omitt #6 check-ball.
-Aluminum forward accumulator-piston and new pin.
-Repair AFL and TCC valve-train as needed.
-TransGO Abuse-Valve Plugs (two).
-Sonnax End-Plugs with O-Rings.
-Blocked 3-2 Control and 3-2 Down-Shift Valves.
-Block 4th accumulator with an empty-bore, so that orificed-accumulator fluid will supply constant lubrication to the rear section.
-Torlon Check-Balls (must create a seat with a steel-ball in the separator-plate first).
-Heat-treated reaction-shell/ Sonnax smart-shell.
-Extra-Deep cast aluminum oil-pan.
-Extra-Large ATF oil-cooler.
-The NP261/ NP263 Transfer-cases (non-HD) work well with heavy vehicles.

There is probably more... but thats it off of the top of my head.

Feel free to PM me or use the Phone number I gave you, to discuss specifics.

Thanks Chello!


it's a stock 5.3l going into an '88 half ton 'burb. just a fun camping rig is what they use it for. lots of hwy miles. no serious off roading or towing.
I tried to sell him on an 80e/np241/61/63 but he is on a very tight budget and has the 60e on hand and appears as if it'll bolt right up to the np208. might even be able to use the same drivelines.

I shall attempt my best effort, and if it fails blame his driving habits.

First there are several completely and partially incompatible versions of the 4L60E. For example the earliest 298mm input shaft is completely incompatible with the later 300mm input shaft. And much later models are electrically incompatible; and the '94 model is incompatible with anything else. So, first step is to find out what year his 4L60E is.
By "stock 5.3l" I assume an LS/Vortec engine. The older 298mm 4L60E will not bolt up directly, but requires only a spacer and a little work on the flexplate.

Keep in mind that an "old" 4L60E is just that - OLD, likely worn and weak. Especially the 298mm model. Hooking up an "old" 4L60E to a health 5/3l LS/Vortec, especially in a heavy vehicle, will shred it.

Vorteciroc may have gone overboard on his recommendations as they are building a 4L60E to handle 600+ HP (technically Ft/Lbs). Much more modest rebuild lists are available here.

Not trying to hijack truckdoug's thread, but can this plate be modified to work well?

You see, I've got this friend who bought one in anticipation of his upcoming build, and I, I mean he, can't return it anymore.

If this can't be salvaged, what separator plate do you recommend?

Any separator plate that can use the Earlier plastic clip-on filters for the solenoids is fine.

The Bonded separator plates have the screen held in-place with one side of the bonded paper...
You could carefully cut-out the screens/ modify the plate for the earlier plastic clip-on filters.

Or purchase a TransGo plate if you can not get a GM plate without the bonded gaskets.

The TransGo 46-PLT-96 is widely available and can easily be drilled for different applications. Start with the V8 drilling in the instructions and then follow the additional drilling steps that various builders have posted here.
It uses the snap-in filters.

this 60e is of the same origin as the 5.3, early 2000's silverado 1500

I use the 4L65E 3-4 stack up in 95% of my builds. 7 Raybestos GPZ-105 3-4 frictions (.065 thick) & 6 .095 3-4 steels. this leaves the 3-4 clearance in the .030 range

is the only GM sep plate available....the one with bonded gaskets ?

All of the GM separator-plates are supposed to be getting superseded by the Bonded-Gasket type...

But there may still be some of the older type separator-plates around. I have not looked.

if I order a new one from the dealer....i get the bonded gaskets.....if someone has some NOS let us know !

Why do you not want to use the Transgo plate? It is more resistant to check ball damage.

Just measured them - the stock plate is .029" and the Transgo is .038", so a lot thicker and therefore resistant to check ball damage.

A 4l80e swap is what a friend would do. LOL

yeah thats what we decided to do. came across a deal on a gen 3 six liter with a 4wd 80e. gonna dig into my stash and give him a cast iron adapter that'll fit up an NP241

its funny how projects creep when I get involved.

but why build the thing you kinda want, when you can build something you really want?

Quote worthy...