SC 4L60E IN

2016-04-15

: Sonnax Sc-4L60E-In SC-4L60E-IN 1208 file instruction uploads

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GM 4L60-E PWM

Sure Cure® Kit

Part No.

SC-4L60E

Valve Body Parts

TCC Regulator Valve Kit

77754-04K

Patent Nos. 6,990,996 & 7,104,273

NOTE: This part requires tool kit 77754-R2.

AFL Valve Assembly

77754-09K Patent No. 6,634,377

NOTE: This part requires tool kit 77754-TL.

Pinless Acc. Piston Kit

77998-03K 1-2 & 4th

Patent No. 6,899,211

Servo Release

Check Valve Kit 77701-076

1-2, 3-4 Accumulator Spring

74926

Checkballs 10000-08 (8)

Valve Body Retainer Clip

77754-08

Forward & Reverse

Abuse Bore Plugs

77754-21 (2)

3-4 Relay Valve End Plug

77764-07

Pump Parts

Oversized Boost Valve &

Spacer (.490") Patent No. 6,619,323

TCC Apply Valve Kit

77805E-K

Oversized PR Valve

77917-07

NOTE: This part requires tool kit 77917-TL.

Pump Slide Pivot Pin 65797

Pump Bushing 77005T

Reassembly Parts

D-Ring Servo Seals (5)

Endplay Shims

77406-10 .010"

77409-15 .015"

NOTE: This kit is fully compatible with ‘95-later 4L60-E units with PWM/EC3 (electronically controlled

capacity clutch) control. These can be identied by the 13-pin case connector, PWM/TCC solenoid

and PWM pump (ve solenoids). All components in this kit are compatible ‘93–‘94 non-PWM units

EXCEPT the TCC apply valve 77805E-K installed in the pump. These units can be identied by the

12-pin case connector, only having a 3-2 solenoid in valve body (four solenoids).

The following tool kits are required to install this Sure Cure Kit:

NOTE: Instructions are provided with these tool kits.

Part No.

77754-R2

Reamer

NOTE: For installing TCC regulator valve

kit 77754-04K in units with a .441" dia.

isolator valve where the isolator bore is

not worn.

If the valve measures .473" dia., you have

a GM serviced valve body and have two

reaming options (in either case you also

will need to install Sonnax isolator sleeve

kit 77754-ISO):

• Ream the bore using tool kit

77754-SERV followed by tool kit

77754-RM5.

• Ream the bore with the VB-FIX

reaming xture and tool kits.

F-77754-SERV followed by

F-77754-TL4.

Part No.

77917-TL

•Reamer

•Jig

NOTE: For installing oversized PR valve 77917-07.

Part No.

77754-TL

•Reamer

•CoreDrill4L80-E Only

•ReamerJig4L60-E Only

•ReamerJig4L80-E Only

•DrillGuide4L80-E Only

•DrillBit.051" (not shown)

NOTE: For installing AFL valve kit 77754-09K.

This tool kit also works for 4L80-E AFL valve

repairs.

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

TRANSMISSION Parts

Instructions

CHECK BALL & VALVE BODY PART LOCATIONS

Note:

7 valve body checkball locations

as indicated above.

8th checkball location is in case as

shown in step #13.

Accumulator Valve Train

(not in this kit)

Actuator Feed Limit Valve Kit

(Reamer #

77754-TL

required) TCC Regulator Valve Kits

(Reamer #

77754-R2

required)

1. Bearing and planetary inspection

2. Case and bore prep

3. Servo seals

4. Pressure Regulator Valve

5. Boost Valve

6. Pump body

7. Pump cover

8. TCC apply valve inspection

9. TCC apply valve installation

10. Pinless accumulator pistons

11. Servo check valve

12. Separator plate modification

13. Checkball

14. Forward Abuse Bore Plug22. Forward accumulator

17. AFL valve (tool required)

18. Separator plate modification

19. TCC regulator valve (tool required)

20. Reverse Servo Abuse Bore Plug

21. 3-4 Relay Valve End Plug

22. 3-2 Downshift Abuse Plug

If you need to get this job out the door in a hurry, then just follow highlighted steps below. The other steps are repair

information (to help prevent NO GOs and CBs) & OEM part numbers that you can read at your convenience.

STEPS

Sure Cure Fast Version

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

TIME TESTED • INDUSTRY TRUSTED

STEP 3 SERVO SEALS

Install Viton® Servo D-ring seals.

Discard OEM seal.

Prepare the seal surfaces

on cover and inner housing

as mentioned in previous step.

STEP 1 BEARING & PLANETARY INSPECTION (REASSEMBLY PARTS)

STEP 2 PREPARE CASE, SERVO AND ACCUMULATOR BORES

Inspect bearings for galling

on race and needles

Note:

Bearings can easily be pried open at the crimp.

Ask for Torrington™ Bearing Kit

SBK-G12.

.025" Max.

Inspect planet pins and endplay.

No side to side movement

Use a fine grit stone to remove high spots on case and valve body.

Scuff the accumulator(s) and servo bore with Red ScotchBrite™.

A stiff wire or rod wrapped with material can be spun in a drill.

Note:

Viton

seals require a surface that retains fluid to ensure

long life.

PREP SURFACES BEFORE CLEANING AND FINISH WITH SOLVENT.

Follow the ScotchBrite™

with a wire-wrapped strip

of the parts cardboard or

leather. This will polish

off sharp edges, and

reduce initial seal scuff.

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

TIME TESTED • INDUSTRY TRUSTED

Reaming Instructions

1. Remove and discard the OEM pres-

sure regulator valve.

2. Clamp the pump housing securely to

a bench.

3. Install the reamer and guide 77917-TL

as shown in the figure above.

4. Flood the valve bore and reamer flutes with cutting fluid (Tap

Magic™, kerosene, etc.).

5. Using a “low” RPM (500-600) drill, carefully ream the valve bore. Maintain

a constant moderate clockwise rotation and apply steady forward pressure

until the reamer reaches the bottom of the valve bore. The reamer should

cut easily. Continue to turn the reamer clockwise as it is removed from

the bore. Ream one pass only.

6. Remove any debris and burrs from the bore. Lubricate and install the

Sonnax replacement valve.

STEP 5 BOOST VALVE

STEP 4 REAM & INSTALL PRESSURE REGULATOR VALVE

STEP 6 PUMP BODY PARTS INSTALLATION

Install new

pivot pin

PTFE-coated pump bushing is inserted here as rebuild

option. Butt gap bushing is not suggested unless the pump

has anti-walk ridge. Surfaces must be prepared with #609

Loctite®. Butt gap should be placed at 12 o’clock position

and installed using full end contact on arbor press.

OEM

Also available:

Heavy Duty Slide Spring

77722-01K

Pump Body

Pressure Regulator Valve

4L60-E

Reamer

Late pump

cast feature

Pre-2005 pumps use enclosed

boost assembly WITH the

enclosed sleeve spacer. This is

to set correct sleeve and

spring height and to ensure

correct line pressure.

2005 and later pumps use

enclosed boost assembly

WITHOUT the enclosed

sleeve spacer. This is to set

correct sleeve and spring

height and to ensure correct

line pressure.

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

TIME TESTED • INDUSTRY TRUSTED

STEP 8 TCC APPLY VALVE IDENTIFICATION

STEP 9 TCC VALVE INSTALLATION

PTFE seal resize

Inspect the TCC solenoid seat for cracks.

PTFE seal supplied must be stretched to install into valve

groove. Resize with finger pressure, pre-lube, then resize by

inverting into bore.

Insert 1/8" or up to seal only. Let it stand for a few minutes.

Pump Cover

Double spool

here indicates

non-PWM valve

STEP 7 PUMP COVER IDENTIFICATION

Non PWM

If the casting has two paral-

lel webs, it is NON PWM and

takes valve 77805-K (Not

included in Sure Cure)

PWM

If the casting has a bridge at

this location, use valve

77805E-K in this kit

(See also Step 13).

Remove the relief rivet and clean ball and seat. With severe

contamination, reform the seat by tapping ball into it.

Note:

Don’t forget to replace filter o-ring.

P/N 77805-K is not in this kit!

Photo at right shows the 3 different

OEM 4L60 and 4L60-E TCC apply

valves. Oil circuits differ, so it is critical

NOT TO MISMATCH PWM versus non-

PWM valves. OEM valve materials can

be steel or aluminum, and should not

be used for identification. A double

spool at the indicated location can be

used to determine PWM versus non-

PWM valves.

Sonnax kit 77805E-K, included, can be

used in both early and late PWM

applications. Discard OEM valve and

spring(s), and replace with complete

valve and seal kit.

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

TIME TESTED • INDUSTRY TRUSTED

Page 6 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com

Adjust “A”

Orifice to Suit

Servo

STEP 10 PINLESS SONNAX ACCUMULATOR PISTONS

• If the last three servo casting numbers are 553, 554 or 159,

or any servo with 2.312" to 2.520" small diameter piston,

Sonnax valve installs “as is”.

• If the last three digits are 093, or the servo is a one-piece aftermar-

ket; enlarge the orifice “A” (at center groove) to .120"–.125".

STEP 11 SERVO RELEASE CHECK VALVE

STEP 12 SEPARATOR PLATE 3-4 CLUTCH FEED IMPROVEMENT

OEM pin must be driven from cover.

Plug pin holes by driving either the large or

small steel checkballs into the hole. Lightly

stake the pin bore after installing the ball.

Teflon®

Viton®

Reassembly:

• Pre-1994 - 4th piston - Install dome into case with spring

in pocket.

• 1-2 piston - Install dome into accumulator

body followed by purple spring.

• 1994 later - 4th piston - Install dome into case.

Some units do not have a spring for 4th accumulator.

If OEM had a spring, install into piston pocket.

• 1-2 piston – Install spring(s) into accumulator body,

set piston pocket opening onto spring, dome toward plate.

(Patent Pending)

Viton® rubber D-ring

installs into groove at

closed dome end and

Teflon® plastic installs

into groove at

open-pocket end.

NOTE: Before installing servo release check valve, make

sure the 3rd accumulator checkball capsule is in the case

and there are no leaks. Replace a leaking capsule with OE

p/n 8634400.

• If necessary adjust orice “A” in valve to match servo

being used (see info to right).

• Tapered end goes in rst. Valve must be driven ush with

case surface and must be tight.

• Install into case without included O-ring. If t is loose,

install included O-ring on check valve and reinstall.

• Adjust separator plate orice “C” to match vehicle (see

step 19).

Some cases bores may be oversized. Use o-ring on check

valve for these bores only. If valve goes into bore with-

out resistance, install the o-ring.

Set up the plate to match your vehicle needs:

A larger separator plate feed hole-C- will result

in a shorter 2-3 shift. Too large, and a bumpy

2-3 will result. Locate the 3-4 clutch feed -C-

orice in your plate.

“C” - Transmission 4L60-E

Application Orice Dia.

Regular Duty No Plate

Modication

Moderate

Performance .090"

Maximum

Performance .100"

Check valve can be removed by threading it

(5/16” x 18”) and using a bolt-on slide hammer

or #5 easy out.

The Sonnax check valve will be installed

with the OE 3rd accumulator check valve

(OE part #8634400).

The check valve Installs on top of the OE

3rd accumulator capsule.

4L60-E Spacer Plate

“C” Hole

#24F

STEPS 14-22 STEPS 14 TO 22 INDICATED BY NUMBER ON VALVE BODY

STEP 14:

With forward accumulator cover still

off, remove low-overrun valve and

roll pin.

Pull out the divider plug and replace

with abuse bore plug in kit.

STEP 15:

Reassemble forward accumulator.

STEP 16:

Update shift solenoids, replace o-rings.

Solenoid information in

specifications.

Inspect Bore here

Same procedure as #14

Pull roll pin. Replace with abuse

bore plug in kit.

Case checkball 4th accumulator

pre-assembled

Servo check valve

from step 11

Note alignment holes in plate

Plate with holes is PWM

Plate without holes is not PWM

Orifice “C” for check valve modification in step 20

STEP 13 CHECKBALLS AND ASSEMBLY TIPS

If you are installing this kit in the vehicle, checkballs must be loaded into valve body.

Valve body checkball locations shown here and picture of

checkball and valve body part locations shown before Step 1.

Drill bit used to check

low-reverse clutch clearance

(clutch clearance on spec sheet).

Note checkball locations

Do not use

excessive

lube, as

balls will

not seat

until lube

melts.

Case connector retainer #

77980-01K

Supply 12 volts to TCC

solenoid and WAT here.

TCC valve in pump will

stroke.

Non-PWM

ALF

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com Page 7

TIME TESTED • INDUSTRY TRUSTED

AFL should not have movement Prop the AFL valve

open by 3/32" from

underneath.

AFL visible bore wear EPC solenoid bore wear. Run

tubing cutter around EPC

manifold to raise material.

STEP 17 AFL BORE INSPECTION AND REPAIR

End Plug

Remove EPC solenoid, clean the screen and replace filters in plate.

Example:

Clip installed here after

sleeve installed

Valve

(77754-09K: U.S. Pat.

No. 6,634,377)

Spring

Converter regulator

valve Reamer

77754-R2

Clamp valve body

“lightly” to bench.

AFL assembly

Reaming:

Fill circuits with

ATF or cutting

fluid. Turn reamer

clockwise only!

Use speed handle

and do not push

on reamer.

After sleeve installation

“poodle clip” pushes into sleeve

groove at channel indicated.

Note:

Reamer kit

77754-TL

required. Also works on 4L80-E.

4L60-E uses marked reamer and guide. No pre-drilling required.

STEP 18 AFL BALANCE HOLE MODIFICATION

When AFL valve & sleeve are installed, the AFL balance hole in

plate must be opened with drill supplied in reamer kit.

Enlarge the indicated balance AFL orifice to

.052" with the drill bit supplied in reamer kit.

Page 8 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

STEP 19 CONVERTER REGULATOR VALVE DESIGN VARIATIONS:

1993-Up

.441" diameter

Remanufactured SERV stamped

into casting, valve same O.D. as

12mm wrench (.473”).

DO NOT ATTEMPT TO RE-REAM A

SERV VALVE BODY WITH

77754-R2

Remove OEM converter regulator valve

Ream this bore with

77754-R2

(sold separately)

Lightly clamp to bench, this side up.

Fill circuits with ATF/ cutting fluid.

Turn reamer with speed handle.

Ream, turning clockwise only.

Blow chips free before removal.

Never turn counterclockwise!

If tight assembly, repeat with 500 RPM drill.

“SERV” stamped

here indicates a

“reamed” valve

body

Casting Number

ID-1993 up to 2000 Wide 1st design TCC

regulator exhaust Casting Number

ID 2001 Updated, full annular exhaust

Sonnax valves

repair these

OEM designs

Valves from “SERV”

valve body

2001-Up valve body

1997 EC3to 2000

1996-1997

non-EC3line-up

1994-1995

PWM line-up

1993-1994

non-PWM line-up

Update TCC/PWM

Solenoid to GM P/N 24212690

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com Page 9

TIME TESTED • INDUSTRY TRUSTED

Isolator Valve

PWM

Boost Conv.

Apply

Line Apply

Balance

Exhaust

Regulator Apply

Valve Sleeve

Regulator

Apply Valve

Annular

Grooves

21. Inspect bore for wear at the 3-4 valve using wiggle test as

shown. Replace end plug with o-ringed end plug provided.

STEP 20 NEW PLATE & VALVE APPLICATION

STEPS 21-22 BORE INSPECTION (LEFT: 3-4 RELAY, RIGHT: 3-2 DOWNSHIFT)

22. Remove 3-2 downshift assembly to remove the inner plug

and replace with abuse plug provided.

Do not use the round hole plate on a '01 valve body.

The plate with rectangular slot can be used with '93-'00 valve body.

Regulator Apply

Valve Sleeve

2nd

Clutch TCC

Signal

Line

TCC

Balance

Exhaust

Isolator Valve

Regulator

Valve

Sonnax installed - Non-PWM Sonnax installed - PWM

Page 10 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

Specifications and Rebuild Information:

R & R INFORMATION:

Cooler return line: Top line

Correct Sonnaflow

readings: 1.5-1.7 GPM TCC off, 2.0-2.6 TCC applied

Fluid capacity: Pan removal 5 qts. overhaul 11 qts

Cold climate (-20f. or more) fluid suggestion: 100% synthetic ATF or blend 50%

Suggested system fluid change on all PWM controlled converters: 40,000 miles

Line pressure: P-N-OD idle 55 Max. EPC 190

R idle 64 Max EPC 320 (Average 270-300)

An effective line pressure and pump output test is:

Reverse 600-750 RPM, with maximum EPC

Line pressure should obtain 270 psi, and not drop more than 20 psi or create an unstable gauge.

CONVERTER IDENTIFICATION:

Bolt-on bell housing height on large 300mm converter: 7"

298mm converter height: (hub set on bench to pad surface) 5.875"

300mm converter height: (hub set on bench to pad surface) 6.500"

Year Converter control OEM friction material Converter Code

‘93-’94 on-off paper

‘95-’96 PWM composition carbon G.H,L

‘97 W cars 3.4 EC

woven carbon N,P,F

‘97 298mm truck PWM composition carbon G,H,L

‘98 all EC

woven carbon N,P,F

‘98-2000 EC

woven carbon B,A

CRITICAL TORQUE AND ASSEMBLY SPECIFICATIONS:

Valve body and accumulator to case 06-10 ft. lbs

Pump body 15-20 ft. lbs

Pump to case 15-20 ft. lbs.

Bell housing to case 48-55 ft. lbs. (Sonnax Torx bit #77000-HBK)

OEM CLUTCH/BAND CLEARANCE, ENDPLAY SPECIFICATIONS:

Forward clutch .030" - .063"

3-4 clutch .035" - .083"

Reverse input .040" - .076"

Low-reverse clutch component stack on bench 1.15"- 1.18"

"Rule of thumb for unspecified clutch" allow .010" clearance per friction

(

Note:

Picture 19 Drill bit inserted between clutches with separator plate off, is used to verify low-reverse clearance.)

Servo travel: .075-.125" (band must freewheel over drum when turning output shaft)

Pump slide clearance .0008"-.0020"

Pump vane clearance .002" max.

3rd accumulator check ball tube to case depth 1.653"

Planet side gear clearance .024" max.

Endplay .005" to .036" total unit (combined)

ELECTRICAL:

OHM Readings GM P/N’s

Shift solenoid 20-40 ohms 10478131

TCC PWM solenoid 10-15 ohms 24212690

3-2 downshift solenoid 20-31 ohms 24212327 (‘96 on, 93-95 PWM 9-13)

EPC solenoid resistance 3.5-8 ohms 24209276

TCC solenoid resistance 20-40 ohms N/A

Shift solenoid firing order: 1st gear both on , 2nd 2-3 on, 3rd both off, 4th 1-2 on

Transmission temperature sensor under approximately 100 ohms inhibits 4th, and brings TCC on after 1-2 shift.

800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com Page 11

TIME TESTED • INDUSTRY TRUSTED

Test at

Orifice Plug

Use ATF here to identify leakage

When WAT 3-4 clutch:

No oil loss at checkball,

or base of shaft.

3-4 Clutch

Forward

Overrun Clutch

On non-PWM

pump, air psi

strokes TCC

apply valve.

Plug off forward,

WAT overruns,

No 3-4 piston

movement!

Forward clutch,

No 3-4 apply!

Torque signal:

No leakage from reverse

Reverse:

No checkball leaks

No leaks at torque signal

3-4 clutch: Overrun,

no piston movement

WAT: Verifies

filter and o-ring

Stator Inspection:

If you had an overheated converter or

stator, inspect tube sleeves for cross

leaks. These leaks can be identified by

the WATs and testing the tube by itself.

Place fluid into the

U-shaped cavity over

lo-overrun valve.

No leakage into

U shaped circuit.

Pressurize roll pin

from machined side.

Close off roll pin under the valve

body w/finger.

WET AIR TESTS

Note:

A 100% leak tested shaft,

77918S-K

77918S-1K, are available from Sonnax.

2005 & later stator shafts are not interchangeable

with 2004 & earlier shafts.

07/21/04

Page 12 800/843-2600 • 802/463-9722 • fax: 802/463-4059 • www.sonnax.com

TIME TESTED • INDUSTRY TRUSTED

SC 4L60E IN

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