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4L60E Transmission Rebuild Page 2 of 32

 
Figure 3
Figure 3

Figure 3. Once the pump is out, the band, reverse input drum and input housing can be removed. As you can see in the photo, the reverse input drum is heavily worn. The band was also burned. The drum will be replaced. Inside the case, you can see the rear planetary, the snap ring and the planetary will be removed. A special type of snap ring plier had to be purchased to get the snap ring off the output shaft. It is called a horseshoe retaining ring plier. The set purchased was the Proto J250G. The Proto pliers worked, but the Lisle 44900 would probably have worked better due to a smaller tip. Both are available from Amazon.

The sunshell was removed and discarded, the teeth looked good, but the factory units are prone to failure, and it will be replaced with the Sonnax Smart Shell, part number 77749-02K. When all this was removed, a couple of the bushings that were in the drums just fell out. This transmission was heavily worn and on the verge of a catastrophic failure. Rebuilding it was definitely the correct thing to do.

Figure 4
Figure 4

Figure 4. The large snap ring holding the back half of the rotating assembly was removed with a large screwdriver. The center support was removed with a couple good taps on the output shaft with a deadblow hammer, and the remaining clutches were removed. The forward planetary shaft was heavily worn, and the complete assembly will be replaced with a 5-pinion planetary to strengthen the transmission.

The rear planetary was in good shape, however, it is a 4-pinion planetary and will also be replaced with a stronger 5-pinion planetary.


 
 
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