HP 4L60E 01 IN

Hp-4L60E-01-In HP-4L60E-01-IN HP-4L60E-01-IN 2928 instructions part uploads sonnax-dev

2016-11-22

: Sonnax Hp-4L60E-01-In HP-4L60E-01-IN 1379 file instruction uploads

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Instructions

High Performance TRANSMISSION Parts

PERFORMANCE

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 1

4L60-E, 4L65-E, 4L70-E

Performance Pack

Part No.

HP-4L60E-01

Fits '94-later units

Pump Parts

• Boost Valve with O-Ring, .490"

• Elevated Pressure Regulator Spring

• High RPM Pump Slide Spring

• Spacer

Servo Parts

• 4th Servo Return Spring

• Servo Cushion Spring

• Servo Piston D-Ring Kit

Case Parts

• 3-4 Accumulator Piston Kit

• 3-4 Accumulator Spring

• Servo Release Check Valve

Valve Body Parts

• Forward Accumulator Kit

• 1-2 Accumulator Valve Shim

• TCC Pressure Limiter:

• TCC Valve

• TCC Spring

• Checkballs (8)

• Separator Plate Plugs Not Shown

• Twist Drills Not Shown

Accumulator Parts

• 1-2 Pinless Accumulator Piston Kit

• 1-2 Accumulator Inner Spring

• 1-2 Accumulator Outer Spring

• 1-2 Accumulator Waved Spring

• Accumulator Housing Spacer

The parts listed here may be protected by

one of these patent numbers: 6,619,323

& 6,899,211.

NOTE: For more radical applications

and even greater levels of performance,

combine the Performance Pack with the

Sonnax 2nd Gear Super Hold Servo Kit

77911-03K and 4th Gear Super Hold Dual

Servo Kits 77911-03K & Kit 77767K.

Accumulator Parts

Valve Body Parts Pump Parts

Servo Parts

Case Parts

Before You Begin

1996-1998 4L60-E applications with two solenoids on front of valve body are programmed

for pulse-width modulated (PWM) torque converter clutch (TCC) control. 1998-later

applications are programmed for “partial slip” of the TCC under light load conditions (EC3).

Both applications have clutch friction material specially suited to partial slip conditions. High

performance converters may be built with on/o friction material that should not be allowed

to slip. For converters built with on/o material, it is necessary to disable the partial slip

function of the transmission by reprogramming the computer or modifying the transmission.

e Sonnax TCC pressure limiter is a calibrated pressure-control spring that allows on/o

converter operation without causing converter pressures to go too high. Other common

modications to the TCC regulator bore in the valve body which block the valve or add a

dierent valve/spring combination cause line pressure to apply the converter clutch at double

normal converter pressures. is leads to extra force on the engine crankshaft thrust bearing

and causes TCC piston exing that – over time – leads to broken rivets and converter failure,

as well as trouble codes.

e TCC pressure limiter modication in this kit is the ONLY available modication that

both eliminates PWM/EC3 operation AND regulates converter pressure to acceptable levels.

If you desire to keep OE PWM/EC3 operation, DO NOT install Sonnax pressure limiter.

Ensure correct PWM/EC3 friction material is used in your converter.

With the pressure limiter spring and Sonnax TCC valve from the Performance Pack or the

Sonnax sleeve kit 77754-04K*, TCC apply pressure will be limited to about 100 psi. With the

pressure limiter spring and Sonnax sleeve kit 77754-03K*, TCC apply pressure will be limited

to about 120 psi.

*Kits sold separately.

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 2

PERFORMANCE PACK HP-4L60E-01

Instructions

High Performance TRANSMISSION Parts

PERFORMANCE

Figure 2

OE TCC Regulator Valve Bore

Inspect for wear. Any significant

wear results in line pressure leakage

to exhaust, regardless of valve type.

Figure 4

Sonnax Regulator Valve and Limiter Spring in OE Bore

Figure 5

Sonnax Regulator Valve Sleeve Kit with Limiter Spring in Reamed Bore

Figure 1

“SERV” stamped

here indicates

a reamed valve

body.

“SERV” Valve Body

‘01-Later

‘97–‘00 EC3

‘96–‘97 PWM

‘95–‘96 PWM

‘93–‘94 non-PWM

Valve Body Parts

1. Determine what style TCC valve is in your valve body by comparing valve lineup (Figure 1).

• For ‘93-‘94 Non-PWM: Original valve can be reused, there is no need to install Sonnax TCC Pressure Limiter unless bore is worn. If bore

is worn, it must be reamed and Sonnax sleeve kit 77754-03K* installed.

• For all ‘95-Later: Follow inspection and installation steps.

•

‘96-Later GM Remanufactured “SERV” with Oversized TCC Regulator:

Reference Sonnax guidelines for tool 77754-SERV. See Figure 1 to

identify a SERV valve body.

2. Inspect TCC regulator valve bore for wear (Figure 2). Vacuum testing

is the preferred and most reliable testing method.

3. If the bore is okay, proceed to Step 2 for pressure limiter installation

instructions. If the bore is excessively worn, it must be reamed and

Sonnax sleeve kit 77754-04K* or 77754-03K* installed.

2. Pressure Limiter Installation

CAUTION: Before installing pressure limiter, see "Before You

Begin" section on page one.

a. Locate the PWM hole in the separator plate. Bore this orice with a

1/16" drill bit, then lightly chamfer both sides of the plate.

Install Sonnax small aluminum plug and peen in place with a

hammer (Figure 3).

b. • For un-reamed OE bore, install Sonnax TCC limiter

spring, then the Sonnax regulator valve included in this kit

and OE end plug (Figure 4).

• For bore reamed to accept Sonnax regulator valve/sleeve kit

77754-04K* or 77754-03K*, install Sonnax TCC limiter

spring, then the regulator valve/sleeve kit 77754-04K* or

77754-03K* and discard the regulator valve included in

this kit (Figure 5).

NOTE: Do NOT install inner isolator valve with the

pressure limiter spring.

*Kits sold separately.

CAUTIONCAUTION

PWM TCC Feed or 2nd

Clutch Oil on Non-PWM Units Plug PWM Hole

Figure 3

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 3

PERFORMANCE PACK HP-4L60E-01

Instructions

High Performance TRANSMISSION Parts

PERFORMANCE

3. Pinless Forward Accumulator Installation

a. Remove OE piston, pin and seal and discard (do not reuse the

OE D-ring seal).

b. Plug the pin bore in bottom of accumulator bore by installing

two .238" dia. Sonnax steel balls (Figure 6). Lightly stake pin bore

after driving balls in.

c. Install Sonnax D-ring seal at domed end of piston. Install

Sonnax PTFE seal at open end of piston.

d. Install Sonnax piston and OE spring. Secure with OE cover

and screws (Figure 6).

4. Separator Plate

a. Drill the plate as indicated to the following specications

(Figure 7):

• Hole “A” (3-2 shift) use drill .093" #42.

• Hole “B” (2nd clutch) use drill .093" #42.

• Hole “C” (3rd clutch) use drill .093" #42.

• Hole “D” (4th clutch) use drill .093" #42.

• Hole “E” (AFL balance oil) use drill .052" #55.

b. Install eight Sonnax plastic checkballs in original locations.

5. 1-2 Accumulator Valve Shim Installation

a. Reuse OE accumulator valve spring.

b. Install shim into sleeve pocket, beveled side down. is can be

done by removing the accumulator valve or by simply insert-

ing the shim between the spring and the end of the bore using a

feeler gauge as an installation tool (Figure 8).

Figure 6

Forward

Accumulator

Kit

Steel

Balls

Spring

Screws

Cover

Figure 7

Figure 8

Accumulator

Valve Shim

Feeler

Gauge

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 4

PERFORMANCE PACK HP-4L60E-01

Instructions

High Performance TRANSMISSION Parts

PERFORMANCE

Figure 9

1-2

Accumulator

Waved

Spring

1-2

Accumulator

Piston

with Seals

1-2

Accumulator

Inner

Spring

1-2

Accumulator

Outer

Spring

Accumulator

Housing

Spacer

‘01-Later

Accumulator

Housing

‘94-‘00

Accumulator

Housing

‘93

Accumulator

Housing

Accumulator Parts

6. Pinless 1-2 Accumulator Installation

NOTE: Do not use this accumulator kit with ‘93 housings.

‘01-Later housings need to have the spacer installed,

‘94-‘00 Housings do not need the spacer (Figure 9).

a. Remove piston pin from the 1-2 accumulator housing.

b. OE pin diameter varies. Plug pin hole by driving one appropriately sized

Sonnax steel ball (.236" or .312" dia.) into hole. Discard unused ball.

c. Stake ball in place.

d. Install rubber D-ring toward piston dome. Install PTFE seal toward open end.

e. For '01-later housings, install Sonnax accumulator housing spacer into accumulator body.

f. Install Sonnax inner and outer springs into accumulator body.

g. Set piston pocket opening onto spring, dome toward plate.

h. Install Sonnax waved spring.

Pump Parts

7. PR Boost Valve & Spring Installation

a. Remove OE boost sleeve and springs. Save OE bumper spring for reuse.

WARNING: The OE boost valve sleeve comes in two lengths, depending on year. The

1994-2004 boost sleeve is longer (1.907") and should be replaced with the Sonnax boost

sleeve AND included Sonnax spacer. If spacer is not installed when replacing 1.907"

sleeves, transmission failure will result! For 2005-later applications with 1.810" long OE boost

sleeve, do NOT install Sonnax spacer.

After placing the two O-rings into the grooves on the boost sleeve, pre-lube them

and roll sleeve over bench to resize the O-ring. Assemble correct boost sleeve/spacer

combination, OE bumper spring and Sonnax elevated pressure regulator spring.

c. Insert Sonnax valve into sleeve with nubbed end facing out (Figure 10).

d. Carefully insert sleeve assembly into pump body with the open end toward the two

springs, just deep enough to reinstall OE retainer clip.

8. Pump Slide Spring Installation

Remove both OE pump slide springs from pump housing and replace with Sonnax

spring (Figure 11).

Figure 10

OE Clip

Boost Valve

Assembly

Elevated PR

Spring

O-Rings

Spacer

OE Bumper Spring

Figure 11

High RPM

Pump Slide

Spring

800-843-2600 • 802-463-9722 • F: 802-463-4059 • www.sonnax.com Page 5

PERFORMANCE PACK HP-4L60E-01

Instructions

High Performance TRANSMISSION Parts

PERFORMANCE

Servo Parts

9. Servo Installation

a. Remove OE servo cushion spring and replace with Sonnax servo

cushion spring (Figure 12).

b. Reinstall the conical OE bumper spring if used in your applica-

tion.

c. Replace OE 4th servo return spring under the washer and C-clip

with Sonnax 4th servo return spring.

d. Install rubber D-rings onto servos. Ensure seals are not twisted in

groove.

Case Parts

10. Servo Release Check Valve Installation

e bore in the case is not a critical diameter for OE manufacturing

purposes, so some variations in the t of the check valve are possible. e

O-ring ensures a positive seal in cases with larger bores. e check valve is

installed between the OE checkball capsule and the separator plate. e

check valve DOES NOT replace the OE checkball capsule (Figure 13).

a. Install the check valve, tapered end rst, into the case. If resistance

is felt, tap the check valve in until ush or just below ush with

the case. If it slides all the way in without resistance, remove and

reinstall with Sonnax O-ring (Figure 14).

b. Run a straight edge over the case to verify the check valve is not

sticking up above the case gasket surface.

11. Pinless 3-4 Accumulator Installation

a. Remove accumulator pin.

NOTE: Pin bore is blind in this location, so

there is no need to plug with any checkball.

b. Install D-ring toward dome with PTFE seal toward open end.

Install dome toward case (Figure 15).

c. Install Sonnax 3-4 accumulator spring.

Servo

Cushion

Spring

Figure 12

4th Servo

Return Spring

OE Bumper

Spring

(some models)

OE Return

Spring

OE Servo

Retainer

Ring

OE Spring

Retainer

OE 2nd

Piston OE 4th Apply

Piston

Retaining

Clip

Washer

Use OE 3rd

accumulator

capsule.

Sonnax

77701-076

Servo Release

Check Valve

Install Sonnax

check valve into

bore over OE

capsule.

Installation Location Transparent View

Figure 13

3-4

Accumulator

Piston Kit

3-4

Accumulator

Spring

Figure 15

Servo Release

Check Valve

Figure 14

O-Ring

Groove

HP 4L60E 01 IN

Hp-4L60E-01-In HP-4L60E-01-IN HP-4L60E-01-IN 2928 instructions part uploads sonnax-dev

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