4L60E Repair Guide  - Installation 



Before installing the repaired 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.  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! - Vader - 2006