4L60E Installation Instructions

4L60E INSTALLATION

Before installing the replacement transmission into the vehicle, several items should be addressed. Verify the transmission dipstick is removed from its tube. Drain the transmission oil cooler, since any contaminated oil there or in the lines can ruin your work in very short order.

Transmission cooler and cooler lines must be COMPLETELY flushed prior to installation! Failure to do this can damage transmission and VOID warranty!

Use *Kooler Kleen* - available at most auto part stores!

Tape or retain all wire harnesses, hoses, fuel lines, and cables out of the way of the transmission tunnel to avoid damage. Inspect the flex plate closely for signs of cracking, damage to the starter ring gear, and loose crankshaft flange bolts. Apply a light film of TransGel or Vaseline to the pilot bore of the crankshaft.

As the transmission is hoisted back into position, mind the dipstick tube as you position the transmission. You should also monitor the electrical harnesses, hoses, tubes, and linkages are being kept clear. Align the transmission onto the engine dowels and install several bolts to gently and evenly pull the transmission onto the engine. Torque the transmission to engine mounting bolts to 40 ft/lb. On Vortec engines with a cast aluminum oil pan, torque the lower transmission mounting bolts (threading into the oil pan) to 33 ft/lb.

Apply LocTite 242 or 262 to the threads of the torque converter bolts, and torque the TC bolts to 45 ft/lb. Do not use antiseize compound on these fasteners.

Install the starter closure ring and starter.

Support the engine and transmission from the engine so that the trans jack can be removed safely.

Install AWD adapter and transfer case if equipped. Torque the adapter and transfer case mounting bolts to 33 ft/lb.

Install the cross member and transmission mount. Connect all external wiring, hoses, and linkages to the transmission, transfer case, and mount the neutral safety switch and linkage.

Hang the exhaust loosely.

Install front and rear drive shafts (match-marked). Torque the universal joint strap bolts to 27 ft/lb. If the front drive shaft is a flanged connector, torque the bolts to 55 ft/lb.

Install the oxygen sensors. Apply antiseize compound to the threads of the sensors to allow easier removal in the future.

For AWD and 4WD models, fill the transfer case with 1.9L AutoTrak II oil.

Add five quarts ATF to permit safe start up and to fill the torque converter.

Tighten the exhaust system.

Verify the gear selector is in NEUTRAL, reconnect the battery, and start the engine, Test run on the jack stands to pump fluid to the torque converter, and check and fill the transmission oil level as necessary.

Operate through reverse, all forward ranges, and 4WD (if equipped).

Top off fluid once transmission is warmed fully. Capacity should be 11-14 quarts total.

Lower and test drive in all ranges operate automatically and manually.

Check final fluid level after driving and with a fully warmed transmission.

Happy Motoring!

FLUID CAPACITIES
Ford		Torque Converter (Fluid Capacity)
Transmission	Total Transmission & Converter Fluid Capacity (with Stock Pan)	Converter Size	Capacity
C4	8-10 quarts	7"	2 quarts
C6	10-12 quarts	8"	2 quarts
AOD/AODE	11-12 quarts	9"	2.5 quarts
E4OD/4R100	17-21 quarts **	10"	3 quarts
4R70W/4R75W	12-14 quarts	11"	3.5 quarts
GM		12"	4 quarts
Transmission	Transmission Capacity (with Stock Pan)	13"	5 quarts
TH350	8-10 quarts
TH400	8-10 quarts
Powerglide(PG)	8-10 quarts
TH200R	10-12 quarts
700R4/4L60E/4L70E	10-12 quarts
4L80E	10-12 quarts
Chrysler
Transmission	Transmission Capacity (with Stock Pan)
TF 727	8-10 quarts
A518/46RE	10-12 quarts
TF 904	8-10 quarts
45RFE/545RFE	12-14 quarts
A618 48RE	15-20 quarts**

* This is approximate information only and may not apply to all transmissions. Transmission Depot Inc. holds no legal responsibilities for any problems (mechanical or otherwise) caused by following the instructions on this page.

*Make sure to check and recheck fluid levels after initial test drive..It is possible to have to add more fluid!

Help Reduce Repeat Transmission Problems!

· Flush and Back Flush Transmission Oil Cooler and Cooler Lines!

· Thoroughly Inspect Cooler Lines For Any Kinks!·

Diagnose and Repair ANY Electronic Issues BEFORE Installing New Transmission

If you are experiencing shifting problems:

* Relearn Procedures*

After the shift-adapts are cleared, some units will function normally right away while others must learn how to shift properly. Some must also learn how to engage into forward and reverse without excessive bump. There is a procedure known as “garage shifts” that involves engaging the unit into reverse five times with a 5-second interval, and the same into forward. In some cases, this is all that’s required. The upshift relearn is normally performed with 5-10 shift cycles through all gears at 20-25% throttle angle.

You must flush lines & cooler unit until cleaning fluid is clear and flowing to maximum capacity

If this is not the case, continue to flush cooler & lines until clear.

Once this is done and fluid is filled to proper level, then raise the rear wheels off the ground

and run transmission in reverse for about 20 minutes at idle. This will help a sticky or

sluggish valve free itself up.

Transmissions are shipped free of any debris! Units are tested and inspected before leaving our facility. If unit is retuned and found to be full of metal, or old clutch material, unit will be repaired at customer’s expense.

DO IT RIGHT THE FIRST TIME!

Flush and Back Flush Transmission Oil Cooler and Cooler Lines

Inspect Cooler Lines For Any Kinks - Repair ANY Electronic Issues

It is Recommenced to add a ½ qrt of fluid to Torque Converter prior to installation.

Notice for ALL Electronic Units

Your old transmission failed for a reason, whether it was lack of service (filter & fluid replacement), severe conditions of operation, or external electrical issues (wiring/computer).

My team and I have over 25 years experience buying, selling and building these units since their production began in the early 90’s. We have found that most of these transmissions fail because of an electrical issue.

After your replacement unit is installed, please be sure to clear all codes, including codes in past history (memory codes) before driving. As always, before installation, be sure to thoroughly flush your lines and cooler. In most cases it is always a good idea to install a new external cooler before install.

We are finding that a large percentage of customers are not doing as instructed and clogging valve bodies, shift solenoids & EPC (electronic pressure control) resulting in shift problems and premature failure.

Also, be sure to check all wiring for bare or chaffed wires going to ALL connections. It is a good idea, before plugging in any electric connections, to coat your pin connectors with dielectric grease. Be sure your vehicles ECM (electronic control module) also known as the VCM (vehicle control module) is communicating with transmission to make it operate properly. This unit controls shifting, speedometer operation, and line pressure to your transmission. It must be operating properly in order for it to communicate with transmission.

Be sure that all the above mentioned is checked and double checked and done properly for miles of enjoyment with your transmission.

If you still feel you have a problem, and all of these issued have been checked, feel free to call tech support at 727-868-9462.

*Also, be sure you have signed and faxed/mailed your warranty activation form!

Thank you for choosing Transmission Depot! Your business is appreciated!

Resetting Shift Adapts: Is It Necessary After Installing a Rebuilt Transmission?

In the old days, installing a rebuilt transmission was easy. A mechanic would simply remove the old unit, install the new one, bring fluids up to recommended levels, and collect their fee. That has all changed, however, thanks to modern electronic components that give today’s gearboxes the ability to learn new habits. Nowadays, resetting shift adapt patterns is essential for ensuring a properly functioning vehicle.

When a Shift Adapt Reset is Needed - Resets should be performed after all rebuilt transmission installs. One should also be completed after any service work that involves reprogramming the TCM/PCM or replacing components. Sometimes an aftermarket scan tool can complete the reset just fine on its own. If it can’t, then you will need to do so manually. A basic how-to on this topic follows:

Steps to Completing a Shift Adapt - Fortunately, shift adapts are relatively easy, as long as the technician follows the steps necessary. These can be broken down as follows. Keep in mind that this is a general guide to resetting shift adapts intended to apply to as many vehicle models as possible, and you should always consult the automobile’s manual for special procedures or circumstances.

NOTE: This procedure requires that the vehicle be driven short distances, both forward and backwards. So it should be performed on a lift or in a large outdoors area. Some PCMs may not allow all four wheels to turn if the vehicle is suspended, making it necessary to perform the reset out-of-doors.

The first step is to complete whatever repairs or maintenance brought the vehicle into the shop in the first place. You may want to hold off on a post-service test drive until the shift adapt process is completed.
Make sure to clear all DTC codes from the TCM.
Check the transmission fluid level and temperature. It should be around 150 degrees F (about 65 C) before beginning the process.
Start the vehicle. Set the shift lever in neutral, move it into drive, and then return it to neutral. Wait five seconds, then repeat this process four more times.
Gently increase engine speed to the equivalent of 45 mph, then gently decelerate. Do this five times.
Repeat step five but raise engine speed slightly faster.
Repeat step five but raise engine speed very quickly.
Shut off the vehicle and leave it alone for two minutes or more.

Shift adapt resets are necessary for installing a rebuilt transmission successfully. Failing to take this important step can cause all sorts of problems for your customers, from hard shifting to internal transmission damage. So, take the time to perform this important procedure correctly.

Courtesy of: ETEREMAN