This is a document for my own rebuild of a 2001 Chevrolet Suburban 1500 LT with a 4L60E transmission. The goal of the project was to build a performance-towing, extremely reliable transmission. A lot of parts could have been reused with no issues, significanlty decreasing the total project cost, but I wanted to eliminate any and all common failure points and reduce doubt for any future failures for many thousands of miles.
The final parts bill came to $1,455.65. While that sounds expensive for a 4L60E rebuild, this wasn’t a basic overhaul. In addition to all wear items, seals, bushings, clutches, steels, bearings, electronics, and a new torque converter, I upgraded many of the transmission’s well-known weak points including the sunshell, forward sprag, servos, shift calibration, input drum, and band assembly. The result is a transmission that should be significantly more durable than the original factory unit while retaining stock drivability and towing characteristics.
Parts
98 up 4L60E 4L65E 300mm Chevy GMC Cad 5.3L 6.0L stock stall HD Torque Converter.
I had concerns that there were metal shavings within the torque converter which is known to be nearly impossible to flush. You might be able to take yours to be remanned, or trade in for a reman. I went with a stock stall since I do towing and use my vehicle for utility. A high stall would require more revs before engagement of the engine to the transmission, which is great for racing since that keeps you in the peak power band for better launch performanc.
Total: $193.73
Bushing Kit 4L60, 4L60E, 700R4 85up w/wide SONNAX rear SG 77010-01. 13 Bushings
I could have measured tolerances, but for $30, it was a peace of mind to do. You will require the 4L60E bushing tool kit to push and press in new bushings. Some bushings might be skipped if a hard part is being replaced and already has a new bushing installed.
Total: $32.42
4L60/60E 13 vane PUMP ROTOR KIT 87+ W/ROTOR,SLIDE,VANES,RINGS,GUIDE AND SEALS
This is only good if the pump is still in good shape and has a smooth surface within the pump. Might be able to get away with a rebuild kit that includes the seals and skip this.
Total: $51.95
4L60E 4L60 4L65E 4L70E 4th Gear Super Hold Dual Servo Kit SONNAX 77767K 1982-up
According to some, this helps prevent clutch burnup. Can be skipped if budget is a concern.
Total: $105.39
4L60E Transmission Rebuild – Steel Clutch Kit – 21-Plate Set – Complete Module
Existing steels can be reused if in good condition. However, this requires the ability to tell if they are burned, glazed, pocked, spotted, warped, or in other ways damaged which could be difficult to tell. Most shops replace them in any case.
Total: $68.88
700R4 4L60E 4L65E Performance PowerPiston™ Set Alto Red Eagle® 057960HP 1994-Up
Required replacement for any rebuild. OEM might have the older aluminum/cast part, definitely replace with the rubber-molded part.
Total: $53.85
Sonnax 74480D 4L60 4L65 4L70E Transmission 3rd Accumulator Checkball Capsule
It’s recommended to replace as checkballs can be a weak point where leaks can occur if the ball doesn’t seat well.
Total: $15.61
. 4L60e OVERHAUL KIT 1997-03 gasket set rings and seals
Total: $48.63
9PCS 4L60E 4L65E Transmission Solenoid Kit For 1993-05 GM EPC Shift TCC 3-2 PWM
People state that for full rebuilds it’s recommended to completly replace all electronics since they tend to degrade over time and moving them to remove them sometimes causes internal breaks in the wiring that could be impercetible. At $120, it is a lot but will eliminate any electrical headaches which are a huge pain.
Total: $117.98
77749-02K 4L60E 700R4 4L65E 4L70E Sonnax Smart Shell Sun Shell Heavy Duty 99930
This is supposedly a superior sun shell compared to OEM. It has an additional welded reinforment ring to prevent cracking. It is noticably stiffer than OEM. Requires a new sun shell thrust bearing (included with shell). Replacing this will change your endplay.
Total: $124.49
TransGo Shift Kit GM 4L60E Includes .500″ Boost Valve (4L60E-HD2) 1993-up
This can be skipped if you want an OEM, stock feeling transmission. This does firm up every shift when installed in the default configuration, which helps prevent prevents slipping and wear between shifts which significantly increases transmission life. However, this may cause discomfort if one doesn’t predict the shift points and revs accordingly.
Total: $119.02
Borg Warner 700R4 4L60E 4L65E 4L70E Forward & Low Reverse Sprag Set
This is the recommended replacement as the OEM cage for the forward sprag is a single cage instead of a double cage setup and an improved top and bottom race.
Total: $75.76
4L60E Rev. Input Drum and Band (refurbished) 93+ square hole with wide HE band
This can be skipped if the reverse input drum is perfectly flat (checked with a known flat tool edge) and no scoring or burn marks are present. If you purchase a wide band, you will need a new drum since the normal wear from an OE band will be different if you keep the old drum.
Total: $74.68
BORG WARNER 4L60/4L60E/4L70 CLUTCH PACK 1987 UP ALL EXCEPT 04+ W/6.0
Any hi-energy bands will work.
Total: $84.32
For GMC Chevy Truck 2422942 4L60E Prndl Neutral Safety Switch Mlps 1995-2003
Some people recommend replacing for a full rebuild, I did not.
Total: $20.56
Superior K012 4L65E Billet 2nd Gear Super Servo GM 4L60E 4L70E Transmission 1-2
According to some, this helps prevent clutch burnup. Can be skipped if budget is a concern.
Total: $148.29
LS Engine Transmission 4L60e Bell Housing Bolts Set Kit Also fits 4L80e T56…
The OEM bolts are an E-Torx head, which can be prone to shearing if care isn’t taken to ensure the bolt isn’t seized. Since it’s cheap, just replace them with regular bolts.
Total: $16.23
4L60E 4L65E 4L70E Input Drum Reinforcement Kit 7773351KA GM 4L60 Input Drum Kit
This apparently will help strengthen the input drum shaft and assembly. This replaces two components of the forward clutch apply pistons.
Total: $38.96
4L60E 700R4 Bearing & Thrust Washer Kit with Input Shim Kit & Thick Pump Washer
Recommended to replace all thrust bearings since you’re in there.
Total: $64.90
Grand Total: $1455.65
Tools / Consumables
4L60 4L65 4L70E Transmission Tool – Remove 3rd Accumulator Checkball Capsule
Total: $24.44
Shop Press – get one with enough space to fit the transmission case. You can get away with only using the bushing driver listed below.. But it will take more care and effort to drive bushings in straight. It feels like cheating useing a press.
13 PCS Master Bushing Driver Set Fit for GM 700-R4 4L60 4L65E 4l60E Transmission
Total: $44.92
Turbine Shaft Teflon Seal Installer Tool Kit For GM 700R4 4L60 4L60E 4L65E 4L70
Stator Shaft Teflon Seal Installer/Resizer Transmission Tool For GM 700-R4 4L60E
Try to get these as a single kit if cheaper
Total (turbine): $12.98
Total (stator): $16.46
Lubegard Assemblēē Gōō™ 16 oz. Tub (1 Each) Transmission Assembly Green Blue
You really only need green in Texas, but I wanted to have both in case.
Total: $34.65
Front Pump Alignment Band Transmission Tool For 4L60 4L60E T-1097 J-21368-A New (got caught up in shipping – ended up refunding order)
https://www.amazon.com/dp/B0GN93SGF3?ref=ppx_yo2ov_dt_b_fed_asin_title
Not necessary if you can find a cheap but large hose clamp.
Total: $12.58
Kent-Moore J-24773-1 Transmission Oil Pump Remover End Play Checker 4L60E
Kent Moore J-25022 End Play Adaptor Tool
This was to check endplay – it was basically useless.
https://www.autozone.com/p/valvoline-auto-transmission-fluid-883572/1177604?searchText=atf%20dex
Any Dexron III and up will work, but the working life of Dexron VI is about twice as long, so might as well since it’s empty.
https://www.amazon.com/dp/B08CXLDJN8?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1
Total: $26.99
https://www.amazon.com/dp/B0BSTX72L1?ref=ppx_yo2ov_dt_b_fed_asin_title
Total: $9.95
https://www.amazon.com/dp/B0DR9L11CS?ref_=ppx_printOD_title_dt_b_fed_asin_title_0_0
Needed for certain steps where glazing needs to be knocked off.
Total: $13.99
https://www.amazon.com/dp/B08KRVPMYB?ref_=ppx_printOD_title_dt_b_fed_asin_title_0_1
Needed for certain steps where glazing needs to be knocked off or parts cleaned.
Total: $18.99
https://www.amazon.com/dp/B0F8Q3FRKJ?ref_=ppx_printOD_title_dt_b_fed_asin_title_0_2
When flattening pieces such as the water pump.
Total: $7.99
