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Old 09-15-2020, 10:43 PM   #1
clinebarger
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Tom's 4L60E build

Member Tom shipped his trans to me for a rebuild, Thought I'd share it with the rest of you.....

This is a 1998 298mm 4L60E with a little over 200,000 miles & As far as I can tell.....Has never been rebuilt.

It was in pretty good shape all things considered. Things found.....
*A couple of the Forward Frictions has no friction material at all.
*The Reaction Shaft has quite a bit of wear where the Thrust Washer rides.
*The Front Pump Rotor had ate a pretty good groove in the Pump Cover.
*The rear Sun Gear Bushing, Reverse Input Drum Bushings, And the front Reaction Shaft Bushing were pretty well wiped out. The rest of the bushings are in need of replacement.


The good.......
*The Reverse Input Drum is in PERFECT shape, Kinda surprised!
The 2 Planetary Carriers are great shape, And it has a "High Speed" rear Carrier which was normally reserved for Corvette/Camaro/Firebird units, But I've seen a few '98 truck units have them.
*The 3-4 Clutch was not burnt down, Just a little distressed.

Didn't get the OK on the build 'til after work.....But, I decided to go ahead & get the Case/Extension Housing/Bellhousing cleaned up along with replacing some bushings anyway.


Recently started using Durabond seamless coated bushings, Even though they cost 3-times what generic Chicom bushings costs, I really like them. OE style Clevite & Federal Mogul bushings are getting harder & harder to find "In-Stock" these days.



Forward Frictions......These are made by Allomatic for GM which were chosen over Borg Warner to cut costs, They don't perform like the BW's!!! All the other frictions are Borg Warner save for the 2 Overrun Frictions which are also Allomatic. It will get the latest Borg Warners during the build!

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Old 09-15-2020, 10:59 PM   #2
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Re: Tom's 4L60E build

Damaged Reaction Shaft. Will be replaced with a good Rollerized version from a low mile 2004 4L65E. This will prevent the Thrust Washer from tearing up the shaft & reduces friction in this area.

Also allows use of a 4L65E Sunshell.


Original shaft on the left, And new bushing installed.




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Old 09-15-2020, 11:05 PM   #3
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Re: Tom's 4L60E build

Damaged Pump Cover.....


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Old 09-15-2020, 11:08 PM   #4
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Re: Tom's 4L60E build

High Speed rear Carrier.....

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Old 09-15-2020, 11:11 PM   #5
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Re: Tom's 4L60E build

New Bushings in the Reverse Input Drum & how good the Band surface is....


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Old 09-15-2020, 11:19 PM   #6
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Re: Tom's 4L60E build

New Bushings in the Front Sun Gear.....


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Old 09-15-2020, 11:21 PM   #7
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Re: Tom's 4L60E build

New Bushing in the Extension Housing.....
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Old 09-16-2020, 08:30 AM   #8
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Re: Tom's 4L60E build

They run that thing low on fluid? That pump is pretty tore up.
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Old 09-16-2020, 03:55 PM   #9
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Re: Tom's 4L60E build

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Originally Posted by Bigdav160 View Post
They run that thing low on fluid? That pump is pretty tore up.
I did not.
Totally stock oem trans with 200,400 miles on it. Have had a b&m line pressure adjuster for the last 130k. Never burned any fluid or overheated it either, have an external cooler after the radiator.
Once it started slipping I put the line pressure controller in its highest setting to get another month out of the trans. Who knows if that has anything to do with it.
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Old 09-16-2020, 05:07 PM   #10
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Re: Tom's 4L60E build

Thanks clinebarger for the excellent tutorial....very much appreciated.

That front pump damage,,,,do you have it resurfaced or replaced with a new / good used unit ?

Looking forward to the continuing lesson....

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Old 09-16-2020, 05:14 PM   #11
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Re: Tom's 4L60E build

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Originally Posted by AussieinNC View Post
...very much appreciated.
I feel you share some credit here too. You know why.
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Old 09-16-2020, 09:31 PM   #12
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Re: Tom's 4L60E build

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Originally Posted by AussieinNC View Post
Thanks clinebarger for the excellent tutorial....very much appreciated.

That front pump damage,,,,do you have it resurfaced or replaced with a new / good used unit ?

Looking forward to the continuing lesson....


I buy reconditioned pumps from WIT (Whatever It Takes), I used to have the fixtures to resurface these pumps, But it's not worth my time when you can buy a reconditioned pump for $150 that has a new 13V pump kit & new Stator Bushings.

Whoever machines these does an excellent job & Rotor Clearance is have always been within spec.....Though I check every one!!

They do have Cast Iron Pump Rings installed which I swap them for OE 4L60E ones or if it's a performance/Hi RPM build I use TransGo "Unbreakable" Rings.
Also has a cheap Aluminum pump bushing that gets swapped out for a DuraBond seamless bushing.

I keep good used 300mm pumps around, But 298mm builds have slowed to the point it's not worth keeping any 298mm specific stuff around. Though technically you can swap a 298mm Stator Support into a 300mm pump......But a Sonnax Stator Support is @$100.



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Old 09-16-2020, 09:39 PM   #13
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Re: Tom's 4L60E build

Case came out pretty well, I hate painting transmissions because I hate working on painted transmissions....


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Old 09-16-2020, 09:56 PM   #14
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Re: Tom's 4L60E build

Time for assembly.....

Case Bushing is the first step, Then the Low Reverse Clutch Piston & Return Spring.
WIT didn't have any DuraBond case bushings.....But I had a Clevite one in stock.

Back Geartrian cleaned up, New Torrington Bearings & Lo/Reverse Sprag installed.



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Old 09-16-2020, 10:06 PM   #15
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Re: Tom's 4L60E build

Rear Geartrain & Lo/Reverse Clutch assembly....

The Plastic Thrust on the Lo/Reverse Roller Clutch Race had a little bit of wear.....So I swapped it out for a like new used one....



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Old 09-16-2020, 10:17 PM   #16
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Re: Tom's 4L60E build

Wide Sonnax rear Sun Gear Bushing installed & 4L65E Sun Shell. Note the Hardened Splines....




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Old 09-16-2020, 10:25 PM   #17
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Re: Tom's 4L60E build

4L65E Reaction Shaft & Bearing & 3-4 Clutch Hub. '02-'06 Reaction Shafts are the same whether 4L65E or 4L60E....This one just happened to come out of a actual 4L65E.....


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Old 09-16-2020, 10:35 PM   #18
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Re: Tom's 4L60E build

Front Carrier & Output Shaft installed. Didn't grab a pic of the Front Sun Gear installed as it's separate from the Forward Sprag Assembly on some 98 models....But it did get installed!

Reverse Input Clutch assembled....


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Old 09-16-2020, 10:50 PM   #19
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Re: Tom's 4L60E build

This unit got some water in it Tom, I see no evidence of it operating with water in it.....I guess it's from the Freight Carrier letting it get rained on or it happened after you pulled it???

The Forward Clutch Piston Housing & 3-4 Clutch Return Spring assembly are rusted pretty bad, Had some good used ones in stock!

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Old 09-16-2020, 11:11 PM   #20
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Re: Tom's 4L60E build

Input Drum Assembly.....Leak checked & Cleaned up the Input Drum first....

*Installed the Forward Clutch Housing O-Ring in the Drum (Not pictured)
*Lube Seal
*3-4 Clutch Piston
*3-4 Clutch Apply Housing
*3-4 Clutch Return Spring Assembly
*Forward Clutch Piston Housing
*Forward Clutch Piston
*Overrun Clutch Piston
*Forward/Overrun Return Spring Assembly







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Old 09-16-2020, 11:24 PM   #21
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Re: Tom's 4L60E build

Forward Sprag Assembly, Swapped out the original Single Cage Borg Warner Sprag for a Dual Cage Borg Warner.
*This unit is right before GM switched to SKF Forward Sprags.

Overrun Clutches Stacked, Front Sun Gear Bearing, Then the Sprag Assembly gets installed/Laced into the Overrun Frictions.

Forward Clutches Stacked & Backing Plate installed....




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Old 09-16-2020, 11:41 PM   #22
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Re: Tom's 4L60E build

3-4 Clutch Stack.....

*I use the latest 4L60E Apply & Backing Plates available from GM
*5 Alto .077" Kolene Steels
*This took One .095" GM "OE Treated" Steel to bring the 3-4 clearance to exactly .023", Pretty much the same as a nitrated Kolene steel, But a different color.
*7 Borg Warner High energy frictions




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Old 09-16-2020, 11:58 PM   #23
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Re: Tom's 4L60E build

*New Turbine Shaft Sealing Rings installed.
*Original "68" End-Play selectable washer....This had acceptable End-play before tear down, New Bearings & Eliminating the Thrust under the Reaction Shaft brought it down to an exceptional .010"!!!
*New Input Drum to Stator Bearing.
*Laced the Reverse Input Frictions & Drum onto the Input Drum.

*Input Drum & Reverse Input Drum installed in the Case which involves lacing the 3-4 Frictions onto the 3-4 Clutch Hub....



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Old 09-17-2020, 12:15 AM   #24
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Re: Tom's 4L60E build

Very nice show and tell clinebarger..!!
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Old 09-17-2020, 12:19 AM   #25
clinebarger
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Re: Tom's 4L60E build

*An aftermarket "Corvette/093" 2nd Servo replaces the smaller "553" Servo.
*TransGo SK-4L60E inner cushion springs added inside the original cushion spring.
*4 oil exit slots added to the cushion spring retainer to prevent fluid hydrolock & harsh 1-2 upsifts & 3-2 down shifts.

**Band Clearance is quite loose even with a TransGo Shim, I'll be correcting that in the morning with a Sonnax "Long" Band Apply Pin. Shooting for @ .060" & it has @ .125" now.

Using a new Borg Warner OE replacement High Energy Band.





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