I rebuilt a 4L60E this past summer. It's essentially a 700R4 without the TV cable and governor. The reason for the rebuild was the 3-4 clutch pack fried. I also added some modifications which came in this rebuild kit:
https://www.700r4l60e.com/store/product.php?productid=320&cat=22&page=1
Buy a kit from a rebuilder that knows these transmissions. The rebuilder will typically include the necessary upgrades and "fixes" such as shift, spring and accumulator kits.
Removal, disassembly, re-assembly and re-installation was straight forward. Since it was a full rebuild and the mods I did are supposed to address known issues, no real close part inspection was needed. All the wear parts were included in the kit.
Check out some of this guy's videos for the 4L60E. It'll give you some idea of what's involved with the nuts and bolts of the process:
https://www.youtube.com/user/hiramgutierrez
Besides common hand tools, you'll need some special tools:
1. Lock ring pliers; both straight and angled jaw. You can't get away with Craftsman or cheap HF pliers. Their jaws don't open wide enough to open some lock rings so they clear the retaining groove in some of the larger diameter shafts. I had to buy a set of SK pliers.
2. Spring compressors; some of the clutch packs have springs behind them that need compressing before you can remove their locking rings.
3. Bushing drivers; IIRC, there are around 11 bushings that need to be driven out and new ones driven in. After doing this using the correct bushing drivers, I would not attempt this with improvised tools.
4. Feeler gages or a dial indicator; some of the clutch packs require they be assembled with specific clearances. Input shaft end play also needs to be set within a certain range.
5. Teflon seal installation tools; these seals are solid Teflon rings with need to be stretched over the shaft and then shrunk back after getting them on the input shaft. A local trans shop might be willing to do this for you. You can use scarf cut rings but no one recommends using these.
6. Transmission jack; removing the transmission with a floor jack is do-able but a transmission jack makes it easier to tilt and yaw the trans making it easier to line up with the engine. Long bolts with the heads cut off can be used as line up dowels. Get a cheap ratchet strap as a safety precaution.
7. ATSG manual for the 700R4. This will describe the tear down and re-assembly procedure. If available, get the ATSG update manual for the 700R4 as well. This will describe factory upgrades.
8. Light viscosity assembly goo.
9. I bought some big aluminum baking sheets at a kitchen supply warehouse to use as catch pans while doing the bench work.
Assembly cautions:
1. Installing one-way clutches (sprags) in backwards.
2. Cutting lip seals during installation.
3. Forgetting or putting check balls in the wrong location.
4. Dirt.
Here's a good book for general knowledge. Read this and watch the videos before attempting this:
http://www.amazon.com/Automatic-Overdrive-Transmission-Builders-Swappers/dp/1932494502
https://www.700r4l60e.com/store/product.php?productid=320&cat=22&page=1
Buy a kit from a rebuilder that knows these transmissions. The rebuilder will typically include the necessary upgrades and "fixes" such as shift, spring and accumulator kits.
Removal, disassembly, re-assembly and re-installation was straight forward. Since it was a full rebuild and the mods I did are supposed to address known issues, no real close part inspection was needed. All the wear parts were included in the kit.
Check out some of this guy's videos for the 4L60E. It'll give you some idea of what's involved with the nuts and bolts of the process:
https://www.youtube.com/user/hiramgutierrez
Besides common hand tools, you'll need some special tools:
1. Lock ring pliers; both straight and angled jaw. You can't get away with Craftsman or cheap HF pliers. Their jaws don't open wide enough to open some lock rings so they clear the retaining groove in some of the larger diameter shafts. I had to buy a set of SK pliers.
2. Spring compressors; some of the clutch packs have springs behind them that need compressing before you can remove their locking rings.
3. Bushing drivers; IIRC, there are around 11 bushings that need to be driven out and new ones driven in. After doing this using the correct bushing drivers, I would not attempt this with improvised tools.
4. Feeler gages or a dial indicator; some of the clutch packs require they be assembled with specific clearances. Input shaft end play also needs to be set within a certain range.
5. Teflon seal installation tools; these seals are solid Teflon rings with need to be stretched over the shaft and then shrunk back after getting them on the input shaft. A local trans shop might be willing to do this for you. You can use scarf cut rings but no one recommends using these.
6. Transmission jack; removing the transmission with a floor jack is do-able but a transmission jack makes it easier to tilt and yaw the trans making it easier to line up with the engine. Long bolts with the heads cut off can be used as line up dowels. Get a cheap ratchet strap as a safety precaution.
7. ATSG manual for the 700R4. This will describe the tear down and re-assembly procedure. If available, get the ATSG update manual for the 700R4 as well. This will describe factory upgrades.
8. Light viscosity assembly goo.
9. I bought some big aluminum baking sheets at a kitchen supply warehouse to use as catch pans while doing the bench work.
Assembly cautions:
1. Installing one-way clutches (sprags) in backwards.
2. Cutting lip seals during installation.
3. Forgetting or putting check balls in the wrong location.
4. Dirt.
Here's a good book for general knowledge. Read this and watch the videos before attempting this:
http://www.amazon.com/Automatic-Overdrive-Transmission-Builders-Swappers/dp/1932494502
