Update literature for the 2005 4L60E Pump?? Is there an update manual that goes beyond the ASTG from 2003? I'm looking for a free PDF that covers all the pieces of the conversion from the 2003, non-ISS to the 2006 and up pump design now in use.
I get why GM did it this way, but damnit, it seems I can only find small pieces of literature that cover specifics rather than as a whole. I hope this makes sense. I see similar stories here with the 2005 5-option design. But is there a published handbook that follows the 2003 revised edition? I'm hoping to find literature that covers all compatibility options for the pump circus. I have a 2005 Case that was rebuilt for a 2003 5.3 L. However, the person that originally re-built it used a mish mash of 1st and 2nd design pump parts, and the damn input shaft separated from the drum. It has the 073 cover stamp, the 2nd design stator support and reluctor space with no teeth on input shaft, also it has the long PRV sleeve. Furthermore-I am unclear as to use the wider diameter boost valve or thinner one. I am rebuilding it as a 2003 5.3L V8. Where can I identify what diameter booster to use? I prefer not to use both the valve shift kit and additional Transgo PRV kit for the sleeve and valve. As I have said in my posts before, I do not have a mentor, that is why this forum site is precious to my growing knowledge. Basically, I'm on my own. Please feel free to message me if that is a better option, I know these threads can get overloaded with information.
Thank you again all,

 

This should cover what you are interested in

Basically, the input shaft sealing rings moved to accomodate the feed hole locations that were moved in the stator to make room for the sensor

there are pumps that have no sensor, but still have the altered sealing ring locations.

They must match. You can't mix and match Non ISS spacing parts with ISS spaced parts

the boost valve is also a different length to make room for the electrical plug

 

Nicole, see this thread and the attachment I included there, from 2009 update...

https://ls1tech.com/forums/automatic...ed-thanks.html

I'm building a 2007 core that has the pump with the plug, and the shaft WITHOUT the reluctor/teeth. I'm using the Sonnax Smart Tech drum designed for the 1997-2003 and had to replace either the pump or the input shaft.

I'll try attaching the pdf here... By the way, the stator shaft has an extra hole inside so you can't use it on 2005-2006 and earlier years.

 

Thank you both for the reference material! I'm still baffled that this build I accepted as core supposedly went 150k mi. I think this customer was full of s**t. At any rate, for this 2003 build I am currently doing, I will take the safe road and put a 2003 pump in with 1st design stator and revert to the 1st design input shaft. And of course the longer boost valve sleeve. Only question that remains regarding the pump: which diameter booster valve? the narrow .471" or the wider .506" Is there a right or wrong answer, and what defines which selection is correct. See picture
size differences in valve and sleeve design
Thank you again for your help and patience. This was not covered in the class I took and we used the 4l60 in the course. This is extremely valuable information.

 

I would use the .490 Sonnax boost valve. I've seen those cheap .506" valves wear out quickly. A 2003 pump would use the "early style" Sonnax valve.