Sonnax HP 4L60E Catalog V4

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VOL. 4

Transmission • Converter • Driveshaft

Performance & Heavy-Duty

4L60/E

4L60/E

CONTACT SONNAX

8:30 a.m. to 5 p.m. ET

(800) 843-2600 toll-free

+1 (802) 463-9722 international

info@sonnax.com

WHERE TO BUY

Ready to order? Find out where to purchase

genuine Sonnax products from an online listing

of authorized distributors in the U.S. and beyond.

GET YOUR GEARHEAD ON • WWW.SONNAX.COM

If you think that 4L60/E on your bench can’t be faster, tougher, stronger, think again.

The world has changed and transmission upgrades from back in the day are old news.

Using Sonnax components, performance specialists are bringing this veteran tranny

roaring back to life with jaw-dropping performance and reliability unimaginable even

a decade ago.

With Sonnax at Your Side,

Any Shop Can Build a

Rock-Solid Transmission

4L60

1982

4L60-E

1993

4L65-E

2001

4L70-E

2006

4L75-E

2016

In 2016, Chevrolet Performance introduced a new member of the

4L60/E family with greatly enhanced torque capacity: the 4L75-E.

This transmission was never installed in a production vehicle.

It is available exclusively over the counter from GM dealers and their distributors.

Sonnax components are the foundation of the 4L75-E. When installed in a 4L65-E or

4L70-E, these and other upgrades found in this catalog allow any shop to offer customers

a top-tier transmission that meets or EXCEEDS the capabilities of the 4L75-E.

See page 10 for details.

LEVEL UPGRADES

4L75-E

GET STARTED WITH BUILD CHARTS ON PAGE 10

4L60-E Performance Pack

The Best Sonnax Parts for Performance

& Heavy-Duty Recalibration

• Firmer shifts under load without sacricing low-speed drivability

• Durable parts target commonly worn areas

in the transmission & prevent future damage

• The only way to eliminate PWM function

without over-pressurizing converters (optional)

The Sonnax Performance Pack is a must-have for any heavy-duty vehicle

and the very best foundation for high-performance racing. All components

work together to carefully tune line pressure, accumulator pressure and

shift calibration. It’s the ULTIMATE way to get an impressive transmission

that responds to throttle and increased load with quick, rm shifts.

Pump Parts

• Pressure Regulator Spring

• Boost Valve, .490"

• Pump Slide Spring

Valve Body Parts

• Forward Pinless

Accumulator Piston Kit

• Accumulator Valve Shim

• Torlon® Checkballs

• Separator Plate Drills

• TCC Spring & Valve

(optional for eliminating PWM function)

“The best working performance

units we have done, and that’s

not from me, but my customers.”

B. Bastedo • Advanced Transmission Care

Fits 4L60-E (’94-Later), 4L65-E, 4L70-E

Part No. HP-4L60E-01

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

Accumulator Parts

• 1-2 Pinless Piston Kit

• 1-2 Piston Springs

• 1-2 Waved Spring

1

Heavy Duty

2-3 Shift Valve

Improve Input Sprag & Forward Clutch Durability

• Critical upgrade for all heavy-duty & performance vehicles

• Easy to install

The OE 2-3 shift valve only applies the overrun clutch in D3 3rd Gear.

For greatly improved durability, the redesigned Sonnax valve applies

the clutch in D3 1st, 2nd and 3rd Gears.

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

Found in Stock 4L75-E

Part No. 77754-41

Range Gear OE Valve

Sonnax

Valve

OD

1st OFF OFF

2nd OFF OFF

3rd OFF OFF

4th OFF OFF

D3

1st OFF APPLIED

2nd OFF APPLIED

3rd APPLIED APPLIED

D2 1st APPLIED APPLIED

2nd APPLIED APPLIED

D1 1st APPLIED APPLIED

2nd APPLIED APPLIED

Clutch Application Comparison

“It doesn’t give harsh shifts, just a little something extra.

Very nice product and I highly recommend it.”

D. Tucker • Tucker’s Transmission

Fits 4L60 (700-R4), 200-4R

Part No. 700R4-LB1

• Steel Boost Valve Assembly

• Pressure Regulator Spring

• O-Rings (2)

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

1.907" Sleeve Kit for Early-Style Pumps

Part No. 4L60E-LB1

1.810" Sleeve Kit for Late-Style Pumps

Part No. 4L60E-LB2

• Anodized Aluminum Boost Valve

Assembly

• Pressure Regulator Spring

• O-Rings (2)

Line Pressure Booster Kits

Crisp, Clean Shifts

without Low-Speed Harshness

• Simple, effective parts install with no special tools required

• Ideal for heavy-duty & modied performance vehicles

as well as hard-working daily drivers

• Improved shift feel & durability for fewer comebacks

& customer complaints

These booster kits are uniquely designed for precision pressure control.

At low-end pressures, they deliver normal engagements, normal

light throttle shifts and smooth coastdown shifts. When vehicles

are pushed harder, components progressively increase pressure for

improved clutch holding capacity and increased durability.

22

SmartShell® Heavy Duty Reaction Shell Kit

Solves Multiple Problems in All Performance Applications

• Stops spline stripping

• Prevents hub breakage

• Eliminates planetary bearing failure

Bulky aftermarket shells always fall short when splines continue to strip

and the shells break under stress. A chronic problem with both OE and

thicker aftermarket shells is failure of the rear planetary bearing. From

your daily jobs to extreme builds, the patented SmartShell is the only

way to prevent shell failure AND protect the bearing.

Learn More About Shell Failure

www.sonnax.com/smartshell

This Sonnax video takes you inside

the sun gear shell to see the source

of common failures and learn how

only the SmartShell can stop them all.

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

Part No. 77749-02K

• Sun Gear Shell

• Large Bearing

• Custom Roller Clutch Race

Unbeatable Bearing Protection

To prevent thrust loads from overwhelming the captured planetary

bearing, the SmartShell features a larger bearing and custom

roller clutch race. These parts re-route thrust loads through the

carrier, completely bypassing the delicate bearing.

Heat-treated splines and lugs

deliver outstanding durability.

Slightly thicker shell adds strength

while avoiding excessive weight.

Reinforced hub area

prevents breakage.

3

Red Band Part No. 77700-01

Firmer shifts than OE, high-energy bands.

Kevlar® Band Part No. 77700-01K

Performs like later-model, OE bands with high-energy

material. While the shifts may not be as rm as with a

red-lined band, overall durability is often better, including

in extreme applications.

Choose the Sonnax “Corvette” ratio servo to:

Upgrade from a smaller-ratio stock servo and

add holding power in many street applications.

Balance Durability with Drivability

When Upgrading the 2nd Gear Servo

There are plenty of 2nd Gear servo sizes

available for the 4L60/E, but going for the

biggest isn’t always best. Some large-ratio

servos are not ideal for daily drivers because

they change shift feel TOO much. For most

applications, you have two upgrade options:

the “Corvette” ratio or the Sonnax super hold.

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

Kevlar Band Found in Stock 4L75-E

Extra Wide Intermediate Bands

15% More Holding Capacity for High-Torque Applications

• Ideal for 4x4, heavy-duty & commercial use

• 60% Thicker case anchor design reduces band failure

• Drop-in replacements, no drum modications required

2nd Gear “Corvette” Ratio

Servo Kit

Improved Holding Power for a

Wide Range of Street Applications

• .74 Ratio servo delivers rmer 1-2 & 2-3 shifts than smaller servos

• Exclusive Sonnax servo features Viton

®

D-rings

for more consistent apply & release than stock servos

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

Part No. 77701-04K

Choose the Sonnax super hold servo to:

Upgrade from a stock “Corvette” servo or

add max holding power in extreme applications.

WITH SONNAX

4L60/E

BUILD THE

4-cyl./V-6

(Smallest OE

Apply Area)

.46 Ratio

V-6/V-8

.55 Ratio

4L70-E

.63 Ratio

Corvette

(Largest OE

Apply Area)

.74 Ratio

Sonnax

Super Hold

.87 Ratio

Learn more about OE and aftermarket 2nd Gear servo options by

reading “A New Trick in the Bag” in the Sonnax online tech library.

4

2nd Gear Super Hold Servo Kit

18% More Apply Area than “Corvette” Servo

• Maximizes holding power in 2nd Gear

with more positive 1-2 & 2-3 shifts

• .87 Ratio servo avoids the timing aws & excessive

shock loads found in other aftermarket servos

• Dual seals ensure positive band apply/release

& eliminate cross leaks

• Apply pin seals reduce leakage of 3rd Gear pressure

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

Found in Stock 4L75-E

Part No. 77911-03K

• Piston w/ D-Rings

• Separator w/ D-Rings & O-Rings

• Apply Pin w/ PTFE & O-Ring Seals

Fits 4L60, 4L60-E,

4L65-E, 4L70-E

Found in Stock 4L75-E

Part No. 77767K

• Servo Assembly

• Steel Washer

4th Gear Super Hold Dual Servo Kit

40% More Apply Area

• Patented dual-piston design delivers greater

holding power than stock servo

• D-ring seals prevent pressure loss

• Use with OE, “Corvette” or Sonnax 2nd Gear servo assemblies

super hold servos

UNMATCHED HOLDING POWER & SHIFT PERFORMANCE

COMBINE

FOR

MAXIMUM APPLY AREA • IN-VEHICLE INSTALL • DURABLE BILLET ALUMINUM

55

Affordable, Drop-In Upgrade

Guards Against 3-4 Comebacks

• Thicker backing plate is stiffer than any other option

on the market to stop heat build-up from clutch pack ex

• Ideal for daily drivers & mild street/strip applications

• Upgrades OE 4L60 (700-R4) & 4L60-E to seven frictions

If your customers are experiencing 3-4 clutch failure, you need to

change the parts you’re installing. Sonnax upgrades ELIMINATE this

area as the weak link in 4L60/E transmissions, and the heavy duty

backing plate kit is an easy, effective way to help prevent burn up in

all but the most extreme builds.

The kit works by targeting the root cause of failure: a weak OE

backing plate that exes during apply, allowing heat to build up within

the clutch pack. Old-school aftermarket kits that add friction plates,

but do so with thinner apply and backing plates, only make the ex

worse and do not notably improve 3-4 clutch durability.

Heavy Duty

3-4 Backing Plate Kit

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

Part No. 74140-01K

• Backing Plate

• Apply Plate

Requires ’91-later 3-4

apply ring stamped with

number “7”, measuring

3.671" to 3.682" in height.

Heavy Duty Overrun Clutch Hub

Stop Hub Failure During Deceleration

Engine Braking in D3, D2 & D1

• 2X Thicker than OE clutch hubs to prevent cracking & breaking

in critical areas that engage the input sprag inner race

• Manufactured from high-strength 4140 chromoly steel

• Direct replacement for ’95-later hubs

Fits 4L60, 4L60-E,

4L65-E, 4L70-E

Part No. 74574-HD

For higher-power applications where max

durability AND expanded clutch capacity

are required to prevent 3-4 failure, install

a Smart-Tech® input housing kit.

Prevents Cracking & Spline Stripping

• Chromoly steel sleeve

• Custom overrun piston works

with steel forward piston

• Also available on new,

OE housing with installed

heavy duty input shaft

(see page 15)

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

Part No. 77733-51K

• Reinforcement Sleeve

• Overrun Piston

• Piston Outer & Inner Seals

Input Drum Reinforcement Kit

This kit requires use of a ’97-later stamped steel

forward piston and dual-cage return spring. See

part instructions at www.sonnax.com for details.

6

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

300mm Reluctor Kit Found in Stock 4L75-E

Key Housing Components:

• 3-4 Clutch Anchor Plate

• Input Housing

• Input Housing Reinforcement Sleeve

• Rear Stator Support Bushing

• Overrun Piston

• 3-4 Clutch Apply Plate

• 3-4 Clutch Return Springs

• Socket Head Cap Screws

• Seals (5)

Housing Kit Only Part No. 77733-06K

Housing Kits with Heavy Duty Input Shafts

300mm Non-Reluctor Part No. 77733-11K

300mm Reluctor Part No. 77733-12K

298mm Part No. 77733-10K

These kits require use of a ’91-later 3-4 apply ring,

’97-later ring gear, ’97-later stamped steel forward

piston and dual-cage return spring. 298mm shaft

may require converter/stator modications. See

part instructions at www.sonnax.com for details.

“The Smart-Tech input housing kit is the

best in the business. Have it in my 4L65-E

putting down over 700rwhp. Zero issues,

no slippage and low temps.”

N. Rodriguez • Koncept Motorwurks

SMOKE THE TIRES,

NOT THE CLUTCHES!

Track-proven to 1,000 HP, the

Smart-Tech housing stops backing

plate ex AND expands clutch

capacity for max protection against

burn up. Learn more about upgrading

the 3-4 clutch on page 12.

Limitations of the OE input housing are the root cause of 3-4 burn up in

performance applications. The patented Sonnax Smart-Tech housing

design makes room for a taller clutch pack anchored in place by a

stronger backing plate. Get the most out of your favorite clutches —

the Smart-Tech housing is the only way to increase clutch capacity

AND protect against destructive heat.

Smart-Tech® Input Housing Kit

Upgraded Housing Eliminates 3-4 Clutch Failure

• Increases 3-4 clutch capacity

• Stops 3-4 backing plate exing & distortion

• Protects against fatigue failure

• Prevents housing breakage

• Ends 3-4 retaining ring blow-out

OE

Housing

Sonnax

Smart-Tech Housing

Clutch

Capacity

See the OE Flex - Watch the Demo Video www.sonnax.com/smart-tech-input-housing 77

TV Cable Corrector Kits

Essential for Proper Transmission

Pressure & Shift Timing

• Precisely sets the distance of OE TV cable travel

• Eliminates the need for other high-cost adapter systems

• Choose from Holley® & Edelbrock® style throttle linkage kits

Most aftermarket carburetors and injection systems are not congured to match OE TV cable

pivot travel, leading to incorrect 4L60 transmission pressures and shift timing. Sonnax TV cable

corrector kits reposition the throttle linkage pivot point to duplicate OE travel.

2.84 Input

Carrier Kit

Ramp Up from OE Wide Ratio

to Race-Ready Close Ratio

• Keeps engine in power band on 1-2 & 2-3 shifts

• Delivers longer pull in 1st & 2nd Gears

• Reduces stress on internal parts

• Six-pinion planet loaded with advanced durability features

The shift from 3.06 ratio (1st Gear) to 1.63 ratio (2nd Gear) is a

dramatic RPM drop that causes performance engines to fall out

of their power band. Sonnax’s 2.84 input carrier transforms the

popular 4L60 series from an OE “wide ratio” 3.06/1.63 to a “close

ratio” 2.84/1.55 for game-changing acceleration on the track.

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

Part No. 77284-K

Fits ’06-earlier reaction shafts only

and requires use of OE bearing 8642191

or 24217327 (not included in kit). See part

instructions at www.sonnax.com for details.

AS4-04K

Shown Here

“The Sonnax six-pinion 2.84 planet is

exactly what 60E transmissions need

to further evolve their spot in the

performance world.”

B. Alley • Revolution Race Works

Fits 4L60, Holley® Style Linkage Part No. AS4-04K

• TV Corrector Plate

• Retainer

• Nut

• Bolt

• Washer

• Spring

Fits 4L60, Edelbrock® Style Linkage Part No. AS5-05K

• Bolts (2)

• Washers (2)

• Nuts (3)

• TV Corrector Plate

• Throttle Cable Stud

• Lock Washer

8

heavy-duty shafts

#1 CHOICE FOR HIGH-HORSEPOWER STREET/STRIP BUILDS

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

For 2WD & Corvette Units Part No. 74678L-HD

For 4WD/AWD Units Part No. 74678S-HD

Output Shafts

• High-strength 300M steel shafts with rolled splines

• Specially heat-treated & processed

for maximum toughness

• Torsional design absorbs energy,

reducing peak loads to critical areas

Fits 4L60-E, 4L65-E, 4L70-E (300mm)

77733-12S Found in Stock 4L75-E

For Non-Reluctor Units Part No. 77733-11S

For Reluctor Units Part No. 77733-12S

Fits 4L60, 4L60-E (298mm)

Part No. 77733-10S

Fits ’85-later 298mm units with 30-spline

input shaft. For ’82–’84 units with 27-spline

input shaft, converter and stator shaft will

need to be updated to ’85-later design.

Input Shafts

• High-strength steel shafts with unbroken

performance in thousands of runs

• Shot peened & cryogenically treated

for extreme durability

• Unique design protects against failure

from stress cracks

Rear Stator Support Bushing

Fits 4L60, 4L60-E, 4L65-E, 4L70-E Part No. 77002BT-01

Unrivaled Support for the 20 lb. Input Housing PLUS Long-Term Reliability

Stop struggling with failure-prone bushings and tment issues! Sonnax offers a

wider, drop-in bushing that’s both better-tting — with a closely toleranced I.D.

usually reserved for machined-in-place bushings — AND lined with PTFE to stop

future wear in its tracks.

Input shafts also available pre-installed in

a Smart-Tech input housing. See page 7.

300mm Non-Reluctor

300mm Reluctor

298mm

2WD/Corvette

4WD/AWD

HIGHLY

WEAR-RESISTANT

PTFE LINING

9

HD PICKUP BUILDS

OPTION A

Line Pressure Booster Kit

See Page 2

SmartShell® Heavy Duty

Reaction Shell Kit 77749-02K

Rear Stator Support Bushing

77002BT-01

4th Gear Super Hold Dual Servo Kit

77767K

Heavy Duty 2-3 Shift Valve

77754-41

OPTION B

Performance Pack

HP-4L60E-01

SmartShell® Heavy Duty

Reaction Shell Kit 77749-02K

Heavy Duty 3-4 Clutch

Backing Plate Kit 74140-01K

Rear Stator Support Bushing

77002BT-01

4th Gear Super Hold Dual Servo Kit

77767K

Heavy Duty 2-3 Shift Valve

77754-41

Quick upgrades for big performance

without a big price tag.

Best parts for heavy-duty recalibration

and durability.

OPTION B

OPTION A

Don’t risk throwing products from different

manufacturers into the same tranny when there’s

no guarantee they’re all going to play nice. Installing

Sonnax parts designed to work together is the

BEST and SAFEST way to upgrade a transmission.

Key upgrades for different build levels are below.

Find more components for top-quality repairs

and upgrades on pages 14 and 15.

Improve Transmission Torque Capacity

Whether we’re speaking in terms of torque capacity or

horsepower, what we’re really talking about is modifying the

transmission to withstand the stress it’s being put under. Sonnax

upgrades allow drivers to take full advantage of any vehicle’s

torque/HP, far beyond what stock transmissions can handle.

In 2016, Chevrolet Performance introduced a new member

of the 4L60/E family with greatly enhanced torque capacity:

the 650 ft-lb 4L75-E. Its jump in torque rating over the 495 ft-lb

4L70-E is largely thanks to Sonnax upgrades, the same ones

featured in this catalog:

The 700-R4/4L60/E family of transmissions is the most

popular performance platform in the world, thanks in large

part to Sonnax components that allow them to run reliably

at extreme power levels. The following key areas MUST be

addressed to realize the full potential of these units:

When these Sonnax parts are installed in a 4L65-E or

4L70-E, you’ve landed at the torque capacity of a 4L75-E.

With a few more Sonnax upgrades to enhance performance

and durability — a Sonnax Level 3 build — now you’ve got a

big power tranny that not only EXCEEDS 4L75-E capabilities,

but is moving well into 4L80-E territory. For those on the fence

about swapping transmissions, it’s a great way to avoid the

complications and inefciencies of converting to a 4L80-E.

Continued on Page 12

Kevlar® Extra Wide

Intermediate Band

LEVEL UPGRADES

4L75-ESmart-Tech® Input Housing

& Heavy Duty Input Shaft

Heavy Duty 2-3 Shift Valve

2nd & 4th Gear Super Hold Servos

WITH SONNAX

4L60/E

BUILD THE

10

PERFORMANCE BUILDS

LEVEL 1

For lightly modied

performance/enthusiast vehicles.

OPTION A

Line Pressure Booster Kit

See Page 2

4th Gear Super Hold Dual Servo Kit

77767K

2nd Gear Super Hold

Servo Kit 77911-03K

2nd Gear “Corvette”

Ratio Kit 77701-04K

OPTION B

Performance Pack

HP-4L60E-01

SmartShell® HD Reaction Shell Kit

77749-02K

Heavy Duty 3-4 Clutch

Backing Plate Kit 74140-01K

Rear Stator Support Bushing

77002BT-01

Choose 2nd

Gear Servo

3 SEASONS IN & STILL GOING STRONG AGAINST 900HP • 1,000 FT-LB • AWD

One of the world’s most extreme 4L60/E vehicles, a Sonnax Level 3 build harnesses the

“Hated” Syclone’s huge horsepower and massive torque at track events and road races nationwide.

Upgrades for performance recalibration and durability, no trans removal required.

Most change in shift feel comes from the servos.

Best parts for performance recalibration and durability.

Most change in shift feel comes from the Performance Pack.

OPTION B

OPTION A

Performance Pack

HP-4L60E-01

SmartShell® Heavy Duty

Reaction Shell Kit 77749-02K

Heavy Duty 2-3 Shift Valve

77754-41

4th Gear Super Hold Dual Servo Kit

77767K

2nd Gear Super Hold Servo Kit

77911-03K

Kevlar® Extra Wide

Intermediate Band 77700-01K

Smart-Tech® Input Housing

& Heavy Duty Input Shaft Kit

See Page 7

4WD/AWD Heavy Duty Output Shaft

74678S-HD

2WD & Corvette

Heavy Duty Output Shaft 74678L-HD

2.84 Input Carrier Kit

77284-K

Choose

Output Shaft

LEVEL 3

For all extreme performance

applications (above 450HP).

Performance Pack

HP-4L60E-01

SmartShell® Heavy Duty

Reaction Shell Kit 77749-02K

Rear Stator Support Bushing

77002BT-01

Heavy Duty 2-3 Shift Valve

77754-41

4th Gear Super Hold Dual Servo Kit

77767K

2nd Gear “Corvette” Ratio Servo Kit

77701-04K

Kevlar® Extra Wide

Intermediate Band 77700-01K

Input Drum Reinforcement Kit

77733-51K

Heavy Duty 3-4 Clutch

Backing Plate Kit 74140-01K

LEVEL 2

For moderately modied

performance vehicles (up to 450HP).

1111

Continued from Page 10

Hunt Down Unstable Pressure,

the Real Pump Killer

When running at higher average pressures, the whole

hydraulic system MUST be in top condition to minimize the

risk to the pump vane rings. Pressure pulsation from poor

PR valve control is the real danger, and a sure sign of this

problem is gauge needle-bounce when testing line pressure.

Stabilizing pressure starts with precise valve-to-bore

clearances (PR valve bore wear is common in 4L60/E units)

and a quality, leak-free boost valve. It’s also essential to feed

the boost valve with a properly working (clean) EPC solenoid

and steady AFL pressure to the EPC solenoid.

Installing Sonnax oversized PR valve (77917-06 or 77917-07),

boost valve with O-rings (multiple options) and AFL valve

kit (77754-09K) is highly recommended for resolving pump

pressure problems.

Don’t Get Burned When

Expanding 3-4 Clutch Capacity

Guarding against 3-4 clutch failure has traditionally meant

working within the limited space of the OE input housing.

Squeezing in more frictions requires installing a thinner

backing plate with thinner clutches and steels, BUT:

• Adding friction surfaces reduces the amount of steel

• Steel in the clutch pack helps dissipate heat

• Without enough steel, heat builds up and clutches burn

Adding more, thinner plates increases static holding

capacity by sacricing engaging capacity. Durability

suffers in higher-load applications where more energy

goes into the clutch during the shift.

The ONLY way to expand clutch capacity without

sacricing steel mass is by replacing the OE input housing

with the Sonnax Smart-Tech® housing (see page 7). Its

custom design holds a physically larger clutch pack to

eliminate 3-4 clutch burn up while also guarding against

other common problems.

Take Care of the Servo Band

Switching to a wider band (Sonnax 77700-01 or 77000-01K)

is an ideal capacity/durability upgrade, but NEVER install

a wider band on a used drum. The old band will have

compressed the drum and created a subtle dish on its

surface. When used with a wider band, this dish leads to

slipping in 2nd Gear, glazing and burning, and will eventually

throw off the band adjustment.

Always check band/pin adjustment to prevent band release

problems. Sonnax servo kits include instructions for setting

servo travel between .075" and .125" using a dial indicator

Never shim the servo, as this moves the piston deeper into

the bore where it’s more prone to bottoming out and causing

band failure.

Stop 3rd Accumulator Checkball Leakage

It’s crucial to prevent even minor leaks in the 3rd accumulator

checkball capsule, as these are directly related to band and

3-4 clutch failure. Vacuum testing the capsule (located in the

servo area of the case) with Sonnax vacuum test stand kit

VACTEST-01K is a quick and reliable way to check for leaks.

Reduce Harsh 1-2 Shift Damage

Damage to the band, input/output shafts, sprag, etc. can be

reduced by properly cushioning the large ratio change on the

1-2 shift:

• Never use a 1-2 servo that eliminates the cushion spring

• Never reduce the 1-2 accumulator piston stroke

• Never leave out the 1-2 checkball

• Never over-drill the 1-2 feed hole

Reduce ratio change by converting 1st Gear from 3.06 to 2.84

with Sonnax input carrier kit 77284-K (see page 8).

WITH SONNAX

4L60/E

BUILD THE

12

Help the Rear Ring Survive

by Moving Up to Five Pinions

Increasing the number of planet pinions from four to ve

distributes load more evenly on the sun gear and around the

ring gear. At high torque, this reduces stress/exing of the

ring gear and improves durability.

Control Valve Body Bleeding

The foundation of a good unit is a tight, leak-free valve

body that prevents pressure loss and conserves pump

volume. Since bore wear is common in the 4L60-E series,

ALL circuits should be vacuum tested to identify leaks.

Use Sonnax vacuum test stand kit VACTEST-01K along

with valve body vacuum test plate 77754-VTP, or test

without plate using free vacuum test guides found at

www.sonnax.com/vactest.

Stabilize Transmission Pressure

with a Better Oil Pan

The best deep pan to use is an aftermarket model with a

lter extension to place the lter lower into the oil sump. It

helps prevent air ingestion during hard acceleration, which

can destabilize transmission pressure and lead to slipping.

Optimize Computer Programming

& Tuning with Care

No matter how well-built the unit, poor computer

programming will quickly kill the transmission. It’s vital to be

informed about the many modication options available and

how they affect performance and durability. Here are a few

examples of classic programming pitfalls:

Pressure Control Optimization

Setting incorrect parameters allows line pressure to drop

“off the mapping table” to a minimum range when maximum

pressure is required. It’s a well-intended tuning mistake that

can lead to clutch-roasting pressure drops.

“Torque Management” Mods

This feature often is completely disabled, even though

leaving a little “on” will help maximize driveline durability

without slowing the vehicle. Figuring out the best balance

requires tuning experience and a solid understanding of a

particular vehicle’s setup.

Continuous Slip (EC3) TCC Control

Since higher-stall aftermarket converters aren’t designed for

continuous slip, it might seem reasonable to eliminate this

function. Simple on-off operation can be excessively harsh,

though, especially when the converter is damperless.

A better programming option is disabling the EC3 continuous

slip, while keeping the pulse-width modulated (PWM) TCC

apply so that the converter clutch comes on in a ramped,

controlled manner.

Application Part No.

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

’03–’08 GM051

’01–’02 Annular Lockup GM049

’96–’01 GM048

’95 GM047

’93–’94 GM046

4L60

Electronic TCC GM044

Hydraulic TCC GM043

The core of a powerhouse transmission is a valve

body free of wear and tear. Save time and money with

a quality rebuilt valve body from Sonnax, the BEST

foundation for performance and heavy-duty upgrades.

Remanufactured Valve Bodies

• Completely refurbished with genuine Sonnax parts

• Hydraulically & electronically tested, ready to bolt up

• Limited Lifetime Warranty

Pursue Input Sprag Perfection

You don’t move when the input sprag fails, a critical link

often overlooked during transmission upgrades.

• Install a new sprag assembly that includes new

inner/outer races. Used races may be worn or

manufactured out of spec.

• Easily strengthen and reinforce the sprag by installing

Sonnax heavy duty 2-3 shift valve 77754-41 (see page 2).

• Clean uid is essential for maximum sprag durability.

Make sure the transmission pan has a drain plug, and

change the uid often to prevent micron-sized debris

from undermining sprag engagement.

FIND MORE GREAT ARTICLES, VIDEOS & GUIDES AT WWW.SONNAX.COM

1313

MORE Sonnax Components for Top-Quality Builds

Components listed in RED should always be considered for racing or heavy-duty builds.

On the street and on the track, Sonnax parts are trusted by top shops to work harder, last longer

and deliver the absolute best in transmission performance. For the 4L60/E series alone, more than 200

top-of-the-line components are available for repairs and upgrades. Visit www.sonnax.com for the

complete listing and detailed product information.

Case Parts

60 60E 65E 70E Servo Release Check Valve Kit Tunes 2-3 shift 77701-076

60 60E 65E 70E 3-4 Accumulator Sleeve Kit 77998-01K

60 60E 65E 70E 3rd Accumulator Checkball & Seat 74480D

60 Governor Mostly diesel, OE 8642729 729

60 Governor Gas, OE 8642730 & 8647041 730

60 Governor Gas, 250, 305 & 350 engines, OE 8642731 731

60 Governor Gas, Corvette, Camaro/Firebird, Caprice,

OE 24202117 & 8663388 117

60E Shift Cable Mount Bracket 34913-01

4L60

4L60-E

4L65-E

4L70-E

Part Name Description

Tool

Required

Part No.

Valve Body Parts

60 60E 65E 70E Pinless Accumulator Piston Kit Piston, seals & balls for 1-2 or 3-4 locations 77998-03K

60E 65E 70E Pinless Forward Accumulator Piston Kit Aluminum, dual seal 77987-01K

60 Oversized Accumulator Pin & Reamer Kit Large pin starter kit, includes 10 pins 77999-02K

60E 65E 70E Oversized Accumulator Pin & Reamer Kit Small pin starter kit, includes 10 pins 77754-02K

60 60E 65E 70E 1-2 or 3-4 Accumulator Spring Purple, 5/bag 74926

60 60E 65E 70E 1-2 or 3-4 Accumulator Spring High-strength material, 5/bag 77704S

60 60E Accumulator Valve Train Kit Medium-weight vehicles 77777L-K

60 60E Accumulator Valve Train Kit Heavy-weight vehicles 77777M-K

60 60E 65E 70E Checkball Imidized plastic, .250" dia., 10/bag 10000-08

60E 65E 70E TCC Regulator & Isolator Valve Kit Fits all years & EC3 units Yes 77754-04K

60E 65E 70E TCC Regulator & Isolator Valve Kit 10% Higher apply pressure Yes 77754-03K

60E 65E 70E Isolator Sleeve Kit For worn isolator bore in unserviced VB

or for any factory remanufactured VB Yes 77754-ISO

60E 65E 70E Actuator Feed Limit (AFL) Valve Kit Feeds solenoids Yes 77754-09K

60E 65E 70E Forward & Reverse Abuse Bore Plug Fits two locations 77754-21

60E 65E 70E Forward & Reverse Abuse Valve Kit Improved design, ts two locations 77754-35K

60E 65E 70E 3-2 Control Valve Spring 77754-23

60E 65E 70E Oversized 4-3 Sequence Valve Kit Yes 77964-04K

60E 65E 70E 3-4 Relay O-Ringed End Plug Kit 77964-08K

60E 65E 70E Oversized 3-4 Shift Valve Kit Includes matched spring Yes* 77754-42K

60E 65E 70E EPC Solenoid Harness Adapter Allows plug-and-play installation of

early-style solenoids into ’03-later units 34435-01K

60 TV Plunger Spring 5/Bag 77968-01K

60 Throttle Valve Plunger Valve Kit OEM #94 77966-94K

60 Throttle Valve Plunger Valve Kit Delays 4-3 downshift 77966-94MK

60 TV Cable Corrector Kit 5/Bag AS1-01K

Servo Parts

60 60E 65E 70E Servo Pin Kit Extra long pin, includes seals 77787-02K

*Installation tooling requires the Sonnax VB-FIX reaming xture.

WITH SONNAX

4L60/E

BUILD THE

14

Pump Parts

60 60E 65E 70E Pump Vane Koyo® (OE), 100/bag 1280

60 60E 65E 70E Pump Slide Pivot Pin 5/Bag 65797

60 60E 65E 70E Pump Slide Spring High RPM, replaces 2 OE springs, 5/bag 77722-01K

60 60E 65E 70E Pump Spring Spacer 10/Bag 77917-RV

60 60E 65E 70E Pump Bushing PTFE-coated like OE bushing 77005T

60 60E TCC Apply Valve Kit Non-PWM only, steel with PTFE seal 77805-K

60E 65E 70E TCC Apply Valve Kit PWM only, aluminum with PTFE seal 77805E-K

60 Oversized Pressure Regulator Valve Yes 77917-06

60E 65E 70E Oversized Pressure Regulator Valve Yes 77917-07

60 TV Boost Valve Kit .423" Bore dia., O-ring style 77917-01K

60 TV Boost Valve Kit .471" Bore dia., O-ring style 77917-471

60 TV Boost Valve Kit .500" Bore dia., O-ring style 77917-500

60 Reverse Boost Valve Kit Large ratio, O-ring style K77898

60E 65E Boost Valve Kit .470" Dia., O-ring style, early pump design 77898E-4K

60E 65E Boost Valve Kit .490" Dia., O-ring style, early pump design 77898E-K

60E Boost Valve Kit .421" Dia., O-ring style, late pump design 77898E-14K

60E 65E 70E Boost Valve Kit .472" Dia., O-ring style, late pump design 77898E-16K

60 Elevated Pressure Main PR Spring Higher pressure 77917-08

60E 65E 70E High-Performance PR Spring Higher pressure 77917-10

60 60E TCC Solenoid Snout Kit ’96-Earlier 77942-01K

60 60E Stator Support Shaft Kit 298mm/245mm Converter units, non-reluctor style 77918S-K

60E Stator Support Shaft Assembly 298mm Converter units, reluctor style 77918S-08K

60E 65E 70E Stator Support Shaft Assembly 280mm/300mm Converter units, reluctor style 77918S-09K

60E 65E 70E Stator Support Shaft Assembly 280mm/300mm Converter units, non-reluctor style 77918S-1K

4L60

4L60-E

4L65-E

4L70-E

Part Name Description

Tool

Required

Part No.

Internal Transmission Parts

60 60E 65E 70E Input Drum Reinforcement Kit Includes sleeve & seal only †77733-02K

60 60E Reinforced Input Housing Kit

with Heavy Duty Input Shaft 298mm Converter units 77733-13K

60E 65E Reinforced Input Housing Kit

with Heavy Duty Input Shaft 300mm Converter units, non-reluctor style 77733-14K

60E 65E 70E Reinforced Input Housing Kit

with Heavy Duty Input Shaft 300mm Converter units, reluctor-style 77733-15K

60 60E 65E 70E Billet Forward Clutch Piston For use with OE aluminum overrun pistons 77764-01

60 60E 65E 70E 3-4 Clutch Boost Spring ’88-Later, 10/bag 77763-01

60 60E 65E 70E Wide Reaction Sun Gear Bushing 1.5X Wider than OE bushing 77010-01

60E 65E 70E Captured Front Planetary Bearing .199" Thick black bearing, ’99-later 77747-01

60 60E 65E Rear Planetary Thrust Bearing .140" Thick, ’06-Earlier 77731-09

60E 70E Rear Planetary Thrust Bearing .160" Thick, ’07-Later 77731-10

60 60E 65E 70E Rear Planetary Pinion Pin Solid, 5/bag 77732-02

60 60E Rear Planetary Rebuild Kit 4-Pinion planetary 77731-RK

65E 70E Rear Planetary Rebuild Kit 5-Pinion planetary 77732-RK

60 60E Oil Deector 4-Pinion rear planetary 77731-08

60 60E 65E 70E Bearing Kit ’82-Later SBK-G12

60 60E 65E 70E Front Endplay Shim .015" Thick (input housing to bearing), 10/bag 77409-15

60 60E 65E 70E Rear Endplay Shim .010" Thick (rear ring gear to bearing), 10/bag 77406-10

†Machining Required

FIND MORE GREAT PARTS AT WWW.SONNAX.COM

15

GO BEYOND THE TRANSMISSION WITH SONNAX

CONVERTER

On the road and on the track, Sonnax is the world's #1

full-line supplier of the quality converter components

essential for long-lasting, trouble-free performance.

A performance torque converter is highly specialized

based on the performance characteristics of the

specic vehicle. Unlike many labor-intensive

aftermarket kits, Sonnax kits ensure fast, easy

assembly with predictable tuning adjustments.

From the weekend enthusiast to the hardcore

competitor, Sonnax has you covered!

Performance Converter Kits

Engineered to Deliver Builds that Last

• Widest variety of kits available

• Designed for ease of assembly

• Improve acceleration & durability with condence

• Supreme Sonnax quality in every component

Where to Buy Talk to your local converter shop or performance specialist about rebuilding with

Sonnax components. Contact Sonnax anytime for comprehensive assistance with Sonnax products.

Transmission Unit Converter Core

Spline

Count Details Dampered Part No.

200-4R, 4L60,

4L60-E

GM 245mm 27 Non-Lockup, 298mm No GM-RK-9

GM 245mm 27 Single-Plate Lockup, 298mm, Mounting Ring Yes GM-RK-12

4L60-E

GM 245mm 30 Single-Plate Lockup, 298mm Ye s GM-RK-18

GM 245mm 30 Single-Plate Lockup, 300mm, Mounting Ring Yes GM-RK-13

GM 245mm 30 Single-Plate Lockup, 300mm Ye s GM-RK-17

4L60, 4L60-E

GM 258mm 30 Multi-Plate Lockup, 298mm No GM-RK-498

GM 265mm 30 Multi-Plate Lockup, 298mm No GM-RK-495

GM 245mm 30 Non-Lockup, 298mm No GM-RK-10

GM 245mm 30 Single-Plate Lockup, 298mm, Mounting Ring Yes GM-RK-11

4L60-E, 4L65-E,

4L75-E

GM 258mm 30 Multi-Plate Lockup, 300mm No GM-RK-408

GM 265mm 30 Multi-Plate Lockup, 300mm No GM-RK-405

Additional components may be required when using these kits, see details at www.sonnax.com.

WOVEN CARBON CONVERTER KITS Exclusively from Sonnax!

Multi-plates with authentic, OE-quality woven carbon frictions deliver the ultimate

in performance and durability, and they’re available only from Sonnax. Woven carbon rings also sold separately.

4L60, 4L60-E

GM 258mm 30 Multi-Plate Lockup, 298mm No GM-RK-498WC

GM 265mm 30 Multi-Plate Lockup, 298mm No GM-RK-495WC

4L60-E, 4L65-E,

4L75-E

GM 258mm 30 Multi-Plate Lockup, 300mm No GM-RK-408WC

GM 265mm 30 Multi-Plate Lockup, 300mm No GM-RK-405WC

16

DRIVELINE

Once you’ve increased engine and transmission performance,

get the power down to the ground with premium-quality

Sonnax driveline components.

TUBING

WELD YOKES

FLANGE YOKES

BONDABLE YOKES

FIND PARTS & TECH RESOURCES AT WWW.SONNAX.COM

Aluminum Tubing & Yokes

Sonnax is America’s #1 source for aluminum aftermarket

driveshaft components, every piece made to exacting

quality standards you can trust.

• 6061-T6 Aluminum components enhance drivetrain strength & durability

• .125" Wall tubing improves torque yield strength,

helping get the power to the ground

• Precision-machined, quality parts for trouble-free performance

Where to Buy Ask for Sonnax aluminum components from your

local driveshaft shop. Contact a Sonnax product specialist for help

with driveshaft component selection.

Fits GM 27-Spline,

Bushing-Style Tailshafts

Part No. T3-3-4281HP

Length: 6.94"

Seal Diameter: 1.503"

U-Joint Series: 1350

This yoke will t the majority of 4L60/E applications,

and Sonnax offers many other sizes and styles. For help

selecting the right slip yoke, visit www.sonnax.com/slip-yokes.

Where to Buy

Purchase Sonnax slip yokes from transmission

parts distributors and driveshaft shops.

Performance Slip Yokes

Affordable, High-Quality Upgrade

for HD/HP & Everyday Builds

• Forged & fully machined from billet steel

for enhanced strength & durability

• Leak-free plug tested to 40 psi for optimum sealing

• 1330 & 1350 Series yokes forged from CHROMOLY steel

Sonnax slip yokes set the standard for incredible

performance and value — a winning combination you

won’t nd anywhere else. It’s the best way to greatly

increase strength and durability in a wide range of

high horsepower and torque capacity vehicles.

Installing Sonnax yokes in routine transmission

builds also helps prevent comeback complaints like:

• Leaking from the back of the transmission

• Noise, vibration and harshness

• Clunking and shudder

17

4L60/E Performance & Heavy-Duty Product Guide Vol. 4

Sonnax • 2 Imtec Lane, Bellows Falls, VT 05101 USA

Contact Sonnax 8:30 a.m. to 5 p.m. ET • (800) 843-2600 • (802) 463-9722 • fax (802) 463-4059 • www.sonnax.com CAT-HP-4L60E4

A Marmon / Berkshire Hathaway Company

©2018 Sonnax Transmission Company, Inc.

Get Your Gearhead On

www.sonnax.com

FIND BUILD CHARTS IN THIS CATALOG ON PAGE 10

& ONLINE AT WWW.SONNAX.COM/4L60E

4L60/E

BUILD THE