GM 4L60 / 4L60E Rebuild Procedures Manual

GM 4L60E/4L60 (700R4) Rebuild Procedures Written by: Clifford McCormick

©2003 ATRA. All Rights Reserved. Printed in U. S. A. iii 4L60E/4L60 Rebuild Procedures Program Introduction… The General Motors 4L60 (also known as the THM700R4) has been with us now for over two decades and, along with the completely computer controlled 4L60E version, has quickly become one of the most widely used late-model GM rear wheel drive transmissions found in cars and lighter-duty pickup trucks. This unit’s time-tested durability and wide gear ratio spread of from 3.06:1 to 0.70:1 make it the perfect unit for a really wide range of different applications. Although many of the head or lead rebuilders in today’s transmission shops ‘cut their teeth’ on this unit, many rebuild technicians join our industry each year, and usually need to find their way through this unit pretty quickly since it’s definitely one of the ‘bread-and-butter’ transmissions, one that brings a lot of work into your shop. There may be parts of the rebuild process that you are not very familiar with, or you may be new to this particular type of transmission. In either case, you need some point of reference- something that will show you how to proceed when you are not sure (or have no idea whatsoever), and that is exactly what this book is designed to do. You will not find a photocopied section out of a factory manual between these covers. In fact, you will notice a substantial difference between the book you are holding and any other books written on the subject. This is because, as this book was being written, the author was rebuilding a 4L60E step by step as he was writing this book. This helped assure that there would be no missing steps (and it was also real handy for taking pictures along the way…). This book was written for transmission rebuilders by a transmission rebuilder, in plain English rather than complex ‘factoreze’ terminology. Although a 4L60E was used throughout most of these pages, the areas where the 4L60 procedures substantially differ from the 4L60E procedures or assemblies will have a separate 4L60 section. So, whether you’ve already done a few of the 4L60E units, or are about to tackle your first one, this book will show you how to get through the sticky parts of a rebuild, as well as the most thorough way to get through the job, start to finish.

©2003 ATRA. All Rights Reserved. Printed in U. S. A. v 4L60E/4L60 Rebuild Procedures Table Of Contents Unit Disassembly Pump Input Drum Disassembly Input Drum Assembly Reverse Drum Gear Train Case Preparation Valve Body/Governor-4L60 Valve Body-4L60E Unit Assembly Page 1 Page 21 Page 49 Page 55 Page 73 Page 79 Page 91 Page 109 Page 128 Page 140 This program has been designed by the Automatic Transmission Rebuilders Association (ATRA) to be used by qualified automotive transmission technicians. Since the circumstance of its use is beyond ATRA’s control, ATRA assumes no liability for the use of such information or any damages incurred through its use and application. Nothing contained in this program is to be considered contractual or providing some form of warranty on the part of ATRA. No part of this program should be construed as recommending any procedure which is contrary to the vehicle manufacturer’s procedures. ATRA recommends that only certified automotive technicians with experience in transmission diagnosis and repair perform the procedures in this program. This program contains copyrighted material belonging to ATRA. No part of this program may be reproduced or used in any form by any means- graphic, electronic or mechanical, including photocopying, recording, electronic, or information storage-and-retrieval systems- without the express written permission from ATRA. ATRA® and the ATRA® logo are registered trademarks of the Automatic Transmission Rebuilders Association. Public exhibition or use of this material for group training or as part of a school curriculum, without the express written permission of ATRA, is prohibited by law. For information on using this material for independent training programs, contact ATRA at (805) 604- 2000. ©2003 ATRA. All rights reserved. Printed in U.S.A.

©2003 ATRA. All Rights Reserved. Printed in U. S. A. 1 4L60E/4L60 Rebuild Procedures Unit Disassembly Step 1: Place the unit into the holding fixture, if available. Step 2: Use a chisel or large screwdriver to remove the rear seal from the extension housing. Step 3: Remove the output speed sensor if it is still in the extension housing.

©2003 ATRA. All Rights Reserved. Printed in U. S. A. 2 4L60E/4L60 Rebuild Procedures Step 4: Remove the extension housing, and housing-to-case rubber seal. Remove the yoke seal from the output shaft if equipped by tapping on it gently with a large screwdriver. Remove the o-ring from the yoke seal.

©2003 ATRA. All Rights Reserved. Printed in U. S. A. 3 4L60E/4L60 Rebuild Procedures Step 5: Remove the servo cover snap ring. Pull the cover out until the servo cover o-ring is in the snap ring groove. Pull the cover o-ring through the slot in the side of the servo bore with a pick, and rotate the servo cover back and forth while pulling on the o-ring until the o-ring breaks or the servo cover and 4 th piston pop out of the bore. If the o-ring breaks, remove it from the case and the cover and piston should pop right out of the case. Step 6: Remove the rest of the servo components from the servo bore. If the servo assembly appears stuck, carefully pull on the servo pin snap ring with a pair of pliers.

©2003 ATRA. All Rights Reserved. Printed in U. S. A. 4 4L60E/4L60 Rebuild Procedures Step 7: Turn the unit over so that the pan is facing you. Remove the pan and pan gasket from the bottom of the unit. Step 8: Remove the filter by rotating it to loosen the filter neck from the seal, then pulling the filter straight up.

GM 4L60 / 4L60E Rebuild Procedures Manual

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