95 4L60E tranny rebuild

[lockdoc]

This was originally posted on AS.com January 2006


This is the beginning of my pic post of the rebuild. Setup my winter workshop. One of the benefits of bachelorhood. The thing is heavy when you have to carry it 150 feet then upstairs. I'm getting older that's for sure. It's mostly disassembled. I'll post more later. My back hurts.

[lockdoc]

I have sized the pics for easy loading. The 50 or so pics equal a total of less than 2 megs for all you dial-uppers.



REMOVING VALVE BODY-1-2 ACCUMULATOR-WIRING HARNESS. TURNS OUT THERE IS AN ORDER TO PULL THESE PARTS THAT I FOUND GOING ALONG.

A NOTE ABOUT THE VALVE BODY. IT IS ALUMINUM. THE 700R4 IS STEEL. I WOULD SAY INSTALLING A SHIFT KIT WOULD BE EASIER ON THE 4L60E WHILE THE TRANS WAS IN THE VEHICLE DUE TO IT'S MUCH LIGHTER WEIGHT.















REMOVING THE PUMP. THERE IS A PULLER FOR THIS BUT I JUST CAREFULLY PRIED UNTILL IT POPPED.

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REVERSE AND INPUT CLUTCH ASSEMBLY. FIRST REMOVED THE 2-4 SERVOS AND PIN TO LOOSEN 2-4 BAND. GRASP INPUT SHAFT AND REMOVE WHOLE UNIT. SERVO COVER WAS A PITA TO REMOVE. LOTS OF CORROSION DUE TO THE HEAT SHIELD MOUNTED ON TRANNY HOLDING IN THE ELEMENTS.









BURNT 2-4 BAND.



REMOVING THE INPUT SUN GEAR-INPUT CARRIER ASSEMBLY-INPUT INTERNAL GEAR\REACTION CARRIER SHAFT ASSEMBLY-SUN SHELL. THIS AREA WAS HARD TO REMOVE DUE TO CHEWED UP GEARS.









A LOOK AT THE LOW-REVERSE SUPPORT\REACTION CARRIER ASSEMBLY.

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REMOVED THE RETAINING RING TO REMOVE THE LOW-REVERSE SUPPORT\REACTION CARRIER ASSEMBLY.









USED COMPRESSOR TO REMOVE CLIP HOLDING LOW-REVERSE SPRING ASSEMBLY AND REMOVED SPRING.







USED COMPRESSED AIR TO BLOW OUT THE LOW-REVERSE PISTON.

[lockdoc]

REVERSE INPUT DRUM AND INPUT SHAFT\HOUSING.



REMOVED RETAINING RING-REVERSE CLUTCHES-SPRING PACK (USING COMPRESSOR)-REVERSE INPUT CLUTCH PISTON.









INPUT SHAFT\HOUSING. REMOVED RETAINING RING-REMOVED 3-4 CLUTCH PACK (IT HAD 6 CLUTCHES INSTEAD OF 4 LIKE THE 700R4)-REMOVED THE FORWARD CLUTCH RETAINING RING-TURNED UPSIDE DOWN AND DUMPED THE FORWARD CLUTCHES AND SPRAG ASSEMBLY-REMOVED THE OVERRUN CLUTCH SPRING ASSEMBLY(WITH TOOL AGAIN)-REMOVED FORWARD CLUTCH PISTON-3-4 APPLY RING-FORWARD CLUTCH HOUSING.

[lockdoc]

THE ONLY SPECIALTY TOOLS I USED SO FAR. SNAP RING PLIERS FROM SNAP-ON AND A SPRING COMPRESSOR.



DISSASEMBLED AND AWAITING CLEANING AND INSPECTION.

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THESE ARE PICS OF THE PUMP. DISASSEMBLED-CLEANED AND CHECKED-UPDATED THE PRESSURE REGULATOR WITH THE TRANSGO KIT-THE VALVE IN THE MIDDLE







THIS IS THE 2-4 SERVO ASSEMBLY DISASSEMBLED AND CLEANED. USING A C CLAMP MADE EASY WORK OF REMOVING THE RETAINER. I REPLACED THIS WITH A VETTE SERVO AND ALSO MODDED WTH TRANSGO.





THE 1-2 ACCUMULATOR AND PISTON AND THE 3-4 ACC. PISTON AND PIN. ALSO MODIFIED WITH DIFFERENT SPRINGS AND REVERSED THE PISTONS.



DISASSEMBLED AND CLEANED THE VALVE BODY-UPDATED VALVES AND SPRINGS WITH TRANSGO.



I REPLACED ALL THE BUSHINGS IN THE TRANS. RENTED A BUSHING INSTALLER SET MADE FOR THE 4L60E.



THESE ARE THE TEFLON RINGS THAT NEED TO BE REPLACED ON THE INPUT SHAFT AND PUMP STATOR. THEY ARE ONE PIECE AND ARE STIFF. THERE IS A TOOL TO INSTALL AND RESHAPE THEM BUT I DIPPED THEM IN BOILG WATER, STRETCHED THEM TO FIT, THEN USED HOSE CLAMPS TO RESIZE. I USED CARDBOARD CUTOUTS AROUND THE CLAMPS SO THEY WOULDN'T GET NICKED BY THE STEEL. NEXT TIME I'LL GET THE TOOL!

[lockdoc]

YOU MUST SOAK ALL THE CLUTCHES IN TRANNY FLUID BEFORE INSTALLING. THE FLUID IS SOOO RED COMPARED TO WHAT I WAS CLEANING OUT OF THIS TRANS.



THE REST OF THE INSTALL IS BASICALLY LIKE THE DISASSEMBLY BUT CLEANER SO I WON'T POST ALL OF IT. BASICALLY I CLEANED E-V-E-R-Y SINGLE PART INDIVIDUALLY AND INSPECTED AND REPLACED WHERE NEEDED. THE ONE PIC IS OF THE TORRINGTON BEARINGS THAT I REPLACED AS WELL. ONE WAS BURNT OUT IN THE FRONT CARRIER ASSEMBLY WHICH IN TURN TRASHED THE ASSEMBLY. I REPLACED THAT AND THE REVERSE INPUT DRUM. THAT IS THE ONE THAT THE 2-4 BAND RIDES ON. IT WAS VERY BURNT AND WARPED FROM HEAT. THE REST OF THE PARTS USED ARE PART OF A STANDARD REBUILD WITH THE ADDITION OF THE TRANSGO SK KIT AND THE VETTE SERVO. THEY COME WITH THIER OWN INSTRUCTIONS TO FOLLOW AS WELL AS FOLLOWING YOUR MANUALS.







HERE I AM CHECKING CLEARANCES OF A CLUTCH PACK. ALL THE STACKS NEED TO BE CHECKED WHILE INSTALLING. IF THEY DON'T COME OUT RIGHT THERE ARE PARTS AVAILABLE TO CORRECT THE HEIGHT.


NOW I JUST HAVE TO INSTALL IT AND SEE IF IT WORKS!

[lockdoc]

Here you can see what is left of the bearing in the rear and the chipped teeth.



Here you can see the discoloration from heat. You can't see in the pic but the surface is not flat anymore either. It's wavy. This is what the 2-4 band clamps against. The 2-4 servo pin applies pressure to the band and grabs this drum. If it is not flat the band won't grab it properly and it will burnout leaving you with no 2nd or 4th gear.

[lockdoc]

Working like a dog here packing up the portable tranny shop.

[lockdoc]

UPDATE

Dean (LiftedAWDAstro) purchased this van after the rebuild. As of September 2006 the tranny works nice with no problems that I am aware of.

[e7ats]

GREAT WRITE UP BILL!!!!!!!! Tell Faith she is a gooood puppy!!!!

[LiftedAWDAstro]

No issues so far Bill! Awesome job on the rebuild. =D> It shifts nice and firm with easy throttle and easily breaks the rear tires and sends the rear sideways when shifting into 2nd on wet roads! I LOVE IT!!!!!! It still chirps the tires shifting into 2nd on dry pavement and that's with an Auburn posi powering both brand new 235's.