Just rebuilt my 4L60E transmission. It is now a 4L65E. Pics and info inside

n8rsk8r · Jan 20, 2012

I created a thread on another forum thinking I would get some feedback or some tips.. I did get a few pieces of info.. but not much. I will post up what I have over there on that forum. I don't have a full thread completed yet, I just got the trans fully running 100% yesterday (after an afternoon of trans line issues).. so I still need to update.

Trans runs GREAT btw! LOVE the new feel my truck has! Hopefully I can come back and edit if I need to.. like I said I am just cutting and pasting for the moment.

My trans build thread:

*Alto Master Kit 1997 Up 4L60E with Molded Pistions* Alto 4L60E Wide RedEagle PowerBand* 4L60E New Reverse Input Drum with Bearing << turns trans into fully rollarized (like adding roller rockers instead of regular rocker arms to heads..)* 700R4/4L60E Bushing Kit* 700R4/4L60E Thrust Bearing Kit* 700R4/4L60E Thrust Washer Kit
* 700R4 / 4L60E Wide Teflon Rear Stator Support Bushing* 700R4 / 4L60E / 200-4RTeflon Coated Pump Bushing
* 700R4 / 4L60E / 200-4R Pump Seal Retainer
*Super Street Raptor Torque Converter - 4L60E WITH,Stall: 2300
* Torlon Check Balls, Ten 1/4 Inch
*Transgo Performance Valve Body Plate, Type: #32VBP-C.
* OEM Type Replacement Springs
*4L60E Complete Electronic Kit (1996 to 2002)

I ended up getting in addition:

a 3-2 control valve spring (sonnax)

pinless accumulator piston kit (sonnax)

5 pinion front and back pinion gears (OEM)

Beast reaction shell

.. think that is it but will add in later if not..

Some of the pics from last night. I got the garage un-screwed and the cherry picker free. I am wondering how heavy this trans is.. Hoping to be able to lift it to where I need to take it. If I have the time, I will build the bench I was going to do over the weekend..

n8rsk8r · Jan 20, 2012

I guess I have to add some text in here..

I will have a beefier 4L65E when this is done

I have ordered the new 5 pinion gears (rear and front) so all I can do is wait for the parts, and tear down the trans in the mean time. Will probably get the Teflon seals installed while waiting for the parts to come in.

Everything happens for a reason, maybe it was to make sure I get everything in order a bit better before the rebuild..

As promised more pics:

Sonnax pinless accumulators

Started the soak last night thinking I would get the rebuild done this weekend.. oh well they will be living in it soon enough Used aboat a 1 3/4qt of trans juice.. regular to soak parts. I am undecided what fluid to use. I still have 7 quarts of that raptorblood.. not sure. Kinda want to go with Royal Purple syn, I used Mobile 1 syn in my SHO for years.. I think that stuff is decent, but really want to try the purple..

Sprags. The one is taken apart, that is the upgraded 29 element double caged forward sprag. The back is a low / reverse (WIDE) sprag (left side).

13 vane pump rotor kit

Pulled out ready for install

2 5/8 extra wide Alto Red band

reaction carrier shaft with 2 bearings

4L60E New Reverse Input Drum with Bearing

That is where she stands. I am going to go move all my stuff in storage to a climate controlled unit right now, have to get it all moved by end of day.. and tonight is new years so off I go.

I will be updating this thread soon and often.

n8rsk8r · Jan 20, 2012

This trans can hold over 500hp and should I choose to put this trans in another vehicle.. a new converter and taking the valve body off and drilling a hole on the separator plate just a smidge bigger is all that is needed.

forgot about these other pics..

Outer roller torrington bearing in place.

Torrington bearing from the reverse drum in place on the next step up

The rear drum sitting on the shaft ( I am pretty sure a thrust bearing goes here also.. just playing around with the parts.. but not 100% sure either way. )

The good OLE' beast shell on top of it all. You can spin it freely like this. Once I get the new 5 pinion gear sets.. it will be complete.

n8rsk8r · Jan 20, 2012

Since this trans is THE original transmission that came out.. I have a unique opportunity to see what was wrong with IT when I pulled it apart.

What I found in the trans pan when I took it off:

What was wrong with the transmission I just rebuilt:

More goopidy goo..

Check ball landing/seat pics (pitted):

n8rsk8r · Jan 20, 2012

I can't tell you how awesome it is to drive now

Here is what was wrong with the original trans:

-broken 3-2 valve spring
-rear pinion gear had one of the pinions that had slight side to side wobble
-grey goop all over the inside of the trans.. especially in weird and sensitive spaces (pressure switch) < was caked in and around the pads..
-mangled anti-clunk spring
-separator plate was cratered on several of the check ball lands, everyone would have made for a replacement, some were terrible (no stuck ball, or ball through the plate though)

It DID get overhauled at one point in the past it had these updates:

-Bonded pistons & matching spring
-29 element sprag was used

What was weird is that they used the newer sprag, and pistons but did not change out the accumulators. They were both plastic. BOTH!
What I found in the trans pan when I took it off:

I am heading over to get the orings resized and need to pick up a new anti-clunk spring and a new 3-2 valve spring. I am going to see what sonnax offers and do that. I need to go through each valve real quick to make sure there are not any more broken springs.

All for now.

n8rsk8r · Jan 20, 2012

I am running out of time.. I will have to post the rest of what I have later.

Weird electrical crap going on..

The PWM had two "twist on" type butt connectors. I had NEVER seen such a connector in all my travels.. was weird. I will try to see if I still have it, if so I will take a pic or two of it and the connections.

n8rsk8r · Jan 20, 2012

I know most drive Fords here, but this GM transmission is in EVERYTHING..

3/4 clutches bad:

Broken 3-2 control spring:

Plastic accumulator pistons (I had 2!):

And what went in it's place (sonnax pinless accumulator pistons)

n8rsk8r · Jan 20, 2012

It was drawn out too much with waiting for parts and having to call different companies to find out the proper install for their aftermarket parts.

I am sure the Torque Converter was bad, or something wrong with it, and the rear pinion gear was bad. One of the pinions had wobble. I got video of the wobble "noise".

The collar on the OEM reaction shell is gouged/grooved so it was trash:

and since I had bought the digital calipers I figured I would check the claims that the beast is 3X's as thick.. you be the judge. I took multiple readings on the OEM piece because it varied so much.. could have been the way I was holding the calipers so I took multiple readings:

Okay here is the "beast shell".. let you see for yourself:

n8rsk8r · Jan 20, 2012

The last of the thread so far.. I may work on it tonight.. not sure. Hope you have enjoyed so far.. this was my first auto transmission rebuild.

Here is the upgrade I did to the 4L60E to make it a 4L65E transmission.
The beast shell is considered by most as part of this "kit", when I say "most".. like everyone aside from GM.. and maybe even GM at this point..

The parts:

What this has done is change from thrust bushings to thrust bearings (makes the entire trans rollerized) and swaps the 4 pinion planet gears for the 5 pinion planet gears (ALWAYS BUY OEM!!).

Here are the parts involved:

Rear drum (wider w/ torrington roller bearing groove milled into end):

Difference between the update (right) and original (left):

This was another item that was bad, the rear drum. It was grooved on the outside from the band.. so it was junk anyway... I upgraded to the one on the right out of want, and ended up needing it just like the rear 4 pinion that was bad.. I ordered the 5 pinion so I just lucked out!

Front 5 pinion planet gears (replaces a 4 pinion. ALWAYS BUY OEM! The "cheap" pinions that are 5 are weaker than the OEM 4 pinion.. so seriously buy OEM.. you don't want to have to rebuild your trans any time soon):

Rear 5 pinion planet gears (replaces the OEM 4 pinion w/ OEM 5 pinion):

Reaction shaft (rollerized):

The shaft is separate and installs kinda funky through the top with a small twist because of the inner teeth.. talk about one complexly cut item.. the teeth are badass because there is so many different angles to it.. you would have to see it in person to understand what I am talking about.. almost how a diamond is cut..

Groove on back that accepts the torrington bearing that sits on top of the front 5 pinion planet gear.

There is another roller bearing for the back that actually rides on top of the front 5 pinion.. look below, it is part of the reaction shaft rollerizing:

and I am not sure, but 98% sure the Borg Warner 29 element front sprag was part of this upgrade. The rear sprag was okay I am thinking.. but we use a wider rear sprag than originally installed for our trans'.. that is a given now I am pretty sure.. (but don't take that for fact.. always check and the part # is on this thread for both sprags)

raged · Jan 21, 2012

1/2 your photos didn't show up, but looks fun.

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Just rebuilt my 4L60E transmission. It is now a 4L65E. Pics and info inside

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Just rebuilt my 4L60E transmission. It is now a 4L65E. Pics and info inside

n8rsk8r i

n8rsk8r i

n8rsk8r i

n8rsk8r i

n8rsk8r i

n8rsk8r i

n8rsk8r i

n8rsk8r i

n8rsk8r i

raged I like guys who eat meat.

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