Chevrolet and GM Performance Parts - High Performance 4L60 Four-Speed Automatic Transmission Installation Instructions

Chevrolet - HIGH PERFORMANCE 4L60 4-SPEED AUTOMATIC TRANSMISSION INSTRUCTIONS

This sophisticated four-speed is GM’s first (remanufactured), over-the-counter automatic transmission assembly for high-performance vehicles. This page supplies information to help with the installation of this transmission.
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Updated 04-10-2006.
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4L60 Remanufactured Performance Four-Speed Automatic	GM Stock Replacement T56 Six-Speed Manual
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GMPP 4L60 TRANSMISSION INSTALLATION INSTRUCTIONS

Important! Read and follow these instructions!
     In order to achieve proper operation of this transmission in your vehicle, it may be necessary to make adjustments and calibration changes described in these instructions. Failure to perform these adjustments and calibrations may result in poor vehicle performance and possible transmission damage. Additional modifications may be required to install this assembly in a vehicle not originally equipped with a 4L60 transmission.
     This instruction sheet is intended as a supplement to General Motors service manuals, which describe service procedures in detail. It is not intended to replace comprehensive service manuals and parts catalogs which cover GM transmissions and components.
     Service manuals for GM vehicles are available from:
Helm, Inc.
P.O. Box O7130
Detroit, MI 48207
     Please read this entire instruction sheet before starting work to familiarize yourself with the installation procedure. Observe all safety precautions and warnings in GM service manuals when installing the 4L60 transmission assembly. Wear eye protection and appropriate protective clothing. Support the vehicle securely with jackstands when working under or around it. Use only the proper tools. Exercise caution when working with flammable, corrosive, and hazardous materials.
     Some procedures require special equipment and skills. If you do not have the appropriate training, expertise, and tools to perform any part of this installation safely, this work should be done by a professional.

Technical Features

The 4L60 four-speed automatic overdrive transmission assembly is General Motor’s first over-the-counter automatic transmission assembly designed specifically for high-performance vehicles. It has a 3.06:1 first gear ratio that provides quick acceleration, and a 0.70:1 overdriven fourth gear and lock-up torque converter that reduce engine speed and enhance fuel economy during highway cruising.
This heavy-duty transmission is assembled with the following premium components:

• Turbine input shaft shot-peened to improve durability.

• High-strength steel 298mm (11-3/4„) diameter torque converter with furnace-brazed fins.
• Lock-up converter clutch rated for 350 ft.-lbs. torque.

4L60 Transmission Assembly Specifications
Type: Automatic four-speed overdrive with torque converter clutch. Gear Ratios: 1st-3.06, 2nd-1.63, 3rd-1.00, 4th-0.70, Reverse-2.29 Converter Diameter: 298mm (11.7 inches) Converter Stall Torque Ratio: 1.91 Maximum Engine Speed: 6250 RPM Maximum Towing Capacity: 7000 lbs.	Maximum Gross Weight: 8600 lbs. Fluid Capacity: 11 qts. approx. (dry) (Refer to service manual for complete instructions on fluid fill capacity.) Fluid Type: Dextron II Weight (with converter): 164 lbs. (dry), 184 lbs. (wet) Shift Quadrant: P, R, N, D, 3, 2, 1

• High-ratio (0.74:1) servo with increased surface area.
• Valve body calibrated for 5500 rpm upshifts at wide open throttle.
• Stall speed approximately 1800 rpm (will vary with engine output).
• 3-4 clutch pack with upgraded friction material.

Applications

     This assembly is based on the 4L60 transmission (“3FMM” code) installed as original equipment in 1993 Camaro Z28s equipped with optional 3.23:1 rear axle ratio. It is a direct replacement for 4L60 transmissions installed in 1993 model vehicles only.
     With minor modifications, the 4L60 will replace 700R4 transmissions in rear-wheel-drive GM vehicles. The wiring harness in pre-1993 computer-controlled vehicles must be adapted to the 4L60 transmission as described in these instructions. The 4L60 can also be wired for proper operation without a computer in emissions-exempt and off-highway operations (street rods, off-road, trucks, etc.).
     The 4L60 assembly is a replacement for 700R4 transmissions used in Camaros, Caprices, full-sized pickups, and similar vehicles only. It does not replace the 700R4 transmissions installed in Corvettes.
     The 4L60 can also replace 200R4 or short-style Turbo-hydromatic 400 transmission if its rear extension housing is changed as described later in these instructions.

Calibrations

If you are installing this transmission assembly in a 1993 Camaro or Firebird originally equipped with a 4L60 transmission, no calibration changes are necessary. If you are installing this transmission in any other vehicle, you must make the following calibration adjustments to ensure proper transmission operation.
Before installing the 4L60 assembly in the vehicle, remove the transmission oil pan to provide access to the valve body.
Note: It is not necessary to remove the valve body from the transmission.

Fourth Gear Clutch Switch: The 4L60 transmission is assembled with a forth gear clutch switch that is normally open. When installing this transmission in a pre-1993 computer-controlled GM vehicle, this switch must be exchanged for a normally closed switch. Unscrew the original fourth gear clutch switch and replace it with the normally closed switch (P/N 8683502) supplied with the 4L60 transmission assembly. Do not change the switch if you are installing this transmission in a non-computer-controlled vehicle!

Throttle Valve Spring: The throttle valve spring (TV spring) installed in the 4L60 assembly is calibrated for engines equipped with Tuned Port Injection (TPI) or Throttle Body Injection (TBI). If your vehicle’s engine is equipped with a carburetor, you must replace the original TV spring to obtain the proper shift feel.

To replace the TV spring, remove the TV linkage and pull out the roll pin that retains the throttle valve. Remove the throttle valve and TV spring. Replace the original spring with the spring supplied. Reinstall the valve, roll pin, TV linkage, and transmission oil pan.

Wiring Harness

Computer-Controlled Vehicles: The 4L60 transmission’s torque converter clutch (TCC) is activated by an electric signal from the vehicle’s engine control module (ECM). The 4L60 transmission uses a five-pin TCC connector that was introduced on 1993 model vehicles. The wiring harness in a 1983-1992 vehicle with a four-pin TCC connector can be modified to fit the transmission’s five-pin TCC connector as follows:
Using the terminal removal tool supplied with the transmission assembly, remove all of the wires from the five-pin TCC connector wiring harness that is supplied with the transmission. Then transfer the wires from the vehicle’s four-pin TCC connector to the five-pin connector. Remove the wire from the four-pin TCC connector marked “A” and insert it in the “A” terminal of the five-pin TCC connector. Repeat this procedure for the “B”, “C”, and “D” terminals, transfer the wires from the four-pin connector to the same respective terminals on the five-pin connector. (Remove the plug in the five-pin connector’s “C” terminal before transferring the wire.) The fifth terminal “E” is not used in this conversion; do not connect a wire to it.

The 4L60 transmission assembly uses a five-pin TCC connector (right). A pre-1993 wiring harness with a four-pin TCC connector (left) can be modified to work with the 4L60 transmission.
Pin Extractor

Transfer the wires from the four-pin connector to the respective five-pin connector (“A” to “A”, “B” to “B”, etc.). The fifth “E” terminal is not used.

Non-Computer-Controlled Vehicles:

When installing a 4L60 transmission in a non-computer-controlled vehicle, connect the supplied wiring harness for the 4L60 transmission’s five-pin TCC connector to a 12-volt power source through a stop lamp/torque converter switch (P/N 25524845) to allow disengagement of the converter clutch during brake application. (Note: This circuit should be “live” only when the ignition is switched on.) This wiring system will apply the torque converter clutch whenever the transmission is in fourth gear. Do not change the fourth gear clutch switch when installing the 4L60 transmission in a non-computer-controlled vehicle.

Speedometer Calibration Variables such as the vehicle’s axle ratio and tire diameter affect the accuracy of the speedometer. The following speedometer drive gears and are available for the 4L60 transmission:	A spring clip retains the speedometer drive gear on the transmission output shaft. Twelve speedometer driven gears are available for the 4L60 to calibrate the speedometer with various axle ratios and tire diameters.

Throttle Valve Cable

The Throttle Valve (“TV”) cable must be installed and adjusted correctly for proper transmission operation. The TV cable adjustment affects shift point, shift feel, detents, and downshifts.
Adjust the TV cable after the transmission has been installed in the vehicle. Adjustment of the TV cable must be made by rotating the throttle lever at the carburetor or throttle body. Do not use the accelerator pedal to rotate the throttle lever.

Stop engine.
Depress and hold down the metal re-adjustment tab at the engine end of the TV cable.
Move the slider until it stops against the fitting.
Release the re-adjustment tab.
Rotate the throttle lever to its full travel position.
The slider must move (ratchet) toward the lever when lever is rotated to its full travel position.
Check that the cable moves freely. The cable may appear to function properly when the engine is stopped and cold. Recheck after the engine is hot.
Road test the vehicle.

The following components are recommended when installing a 4L60 transmission in a street rod or other vehicle that was not originally equipped a TV cable:
P/N 25515598 - Throttle valve cable
P/N 22504927 - Cable bracket (for Quadrajet carburetor)

Extension Housing

An extension housing (P/N 24214689) is available for the 4L60 transmission that moves the rear transmission mount to the same position as a TH400 (short-style) or 200R4 transmission. This extension housing (“tail shaft”) can eliminate transmission crossmember modifications when replacing a TH 400 or 200R4 transmission with a 4L60 assembly.
Note: When replacing a TH400 transmission, the driveshaft yoke must be changed to fit the 4L60 output shaft.

Related Components

The following components are recommended when installing a 4L60 transmission in a vehicle not originally equipped with a similar transmission:

P/N 15531900 - Indicator (“dipstick”) for B-body (Caprice) and G-body (Monte Carlo, etc.).
P/N 10126485 - Filler tube for above.

P/N 10079807 - Indicator (“dipstick”) for 1982-92 Camaro/Firebird.
P/N 10085252 - Filler tube for above.

P/N 1259475 - Filler tube seal.

P/N 14091903 - Torque converter cover (for 12-3/4„ flexplate).
P/N 15650700 - Torque converter cover (for 14„ flexplate).

P/N 1261968 - Torque converter bolt.

P/N 25524845 - Stop lamp/torque converter switch. (Pic)

P/N 24502513 - Switch Kit, GM instruction sheet (source for this page), 4 and 5 pin TCC connectors, Pin Extraction Tool, TV spring, fourth gear clutch switch (P/N 8683502), and 2 small GMPP decals. (Pic)

Chevrolet’s Additional Installation Information
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