1997 Isuzu Hombre S

1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

1997-98 AUTOMATIC TRANSISSIONS

Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

APPLICATION
TRANSMISSION APPLICATIONS
Application Transmission Model
Chevrolet
Blazer 4L60-E
S10 Pickup 4L60-E
GMC
Envoy (1998) 4L60-E
Jimmy 4L60-E
Sonoma 4L60-E
Isuzu Hombre 4L60-E
Oldsmobile Bravada 4L60-E

IDENTIFICATION
The 4L60-E transmission can be identified by a letter code contained in identification number. Identification
number is stamped on transmission case above oil pan rail on right rear side, or to rear of oil pan. See Fig. 1 .
Identification number contains information which must be used when ordering replacement parts. Transmission
RPO code is M30.

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 1: Locating Transmission Identification Number

Courtesy of GENERAL MOTORS CORP.

DESCRIPTION

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

The 4L60-E is a fully automatic transmission consisting of a 3-element hydraulic torque converter with a
Torque Converter Clutch (TCC). The 4-speed transmission is equipped with 2 planetary gear sets, 5 multiple-
disc clutches, one sprag clutch, one roller clutch and a 2-4 band. See Fig. 2 .

A hydraulic system, pressurized by a variable capacity vane type oil pump, provides pressure required to
operate friction elements and automatic controls. The 4L60-E also contains electronic solenoids to control
hydraulic operations. A Powertrain Control Module (PCM) receives signals from Vehicle Speed Sensor (VSS),
Throttle Position (TP) Sensor, fluid pressure switch assembly, and temperature sensor. These signals help PCM
determine when to switch 2 shift solenoids, 3-2 downshift solenoid, and/or TCC solenoid on or off. PCM can
also control line pressure via pressure control solenoid (force motor).

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 2: Locating 4L60-E Transmission Components

Courtesy of GENERAL MOTORS CORP.

LUBRICATION & ADJUSTMENTS

See TRANSMISSION SERVICING - A/T article in the TRANSMISSION SERVICING section.

ON-VEHICLE SERVICE

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

OIL COOLER FLUSHING

1. If available, fill Line Flusher (J-35944) with solution, and install line flusher to transmission end of cooler
line that feeds bottom fitting of transmission cooler. Connect discharge hose to top cooler line and attach
drain hose to oil drain container. Follow manufacturer's instructions to flush oil cooler and cooler lines.
2. If line flusher is not available, flush cooler and cooler lines with a mixture of clean solvent and water.
Flush cooler in both directions until all old fluid and debris are removed. If necessary, replace plugged or
damaged cooler and/or lines.

REAR OIL SEAL

Removal & Installation

Mark drive shaft for reassembly reference. Remove drive shaft. Pry oil seal from extension housing. Coat
outside edge of NEW oil seal with non-hardening sealer. Using Seal Installer (J-21426), install oil seal. To
complete installation, install drive shaft. Check fluid level.

VALVE BODY

CAUTION: Note valve body bolt length and location during removal procedure.
Transmission case damage may occur if bolts are incorrectly installed.

Removal

1. Remove transmission oil pan. Remove oil filter and "O" ring. Ensure "O" ring is removed from
transmission case. Remove electrical connectors from switches and solenoids, and mark for reassembly
reference. Remove pressure switch assembly. Remove detent spring bolt. Remove detent spring. Remove
valve body bolts. Note length and location of bolts for installation reference.
2. Note direction of manual valve link. Remove manual valve link from manual valve at valve body. See
Fig. 3 . Remove valve body. Note location of check balls. DO NOT lose balls. See Fig. 4 and Fig. 5 .

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 1997 Isuzu Hombre S
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Fig. 3: Installing Manual Valve Link

Courtesy of GENERAL MOTORS CORP.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 4: Locating Valve Body Check Balls

Courtesy of GENERAL MOTORS CORP.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 5: Locating Check Balls In Case

Courtesy of GENERAL MOTORS CORP.

Installation

1. Coat check balls with petroleum jelly. Install check balls in proper locations on separator plate. See Fig. 4
and Fig. 5 . Install manual valve link. Ensure manual valve link is properly seated in manual valve. See
Fig. 3 . Improper positioning may prevent vehicle operation in "D" range.

NOTE: Improper positioning of throttle valve link will result in erratic shift points
or high oil pressure.

2. Install valve body and retaining bolts. Tighten all bolts to specification. See TORQUE
SPECIFICATIONS . Lubricate oil filter "O" ring with ATF before installation. To complete installation,
reverse removal procedure. Fill transmission with fluid.

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

2-4 SERVO ASSEMBLY

Removal & Installation

Install Piston Compressor (J-29714) on oil pan. Compress servo cover, and remove retaining ring. See Fig. 6 .
Remove servo cover and "O" ring. Remove 2-4 servo assembly. To install, reverse removal procedure. For
servo pin length check, see 2-4 SERVO ASSEMBLY under TRANSMISSION DISASSEMBLY .

Fig. 6: Compressing Servo Cover

Courtesy of GENERAL MOTORS CORP.

TROUBLE SHOOTING

NOTE: For testing and diagnostic procedures of electronic components, see AUTO
TRANS DIAGNOSIS article.

NOTE: For clutch and band applications, see CLUTCH & BAND APPLICATION CHART .

SYMPTOM DIAGNOSIS

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

1st Gear Only, No Upshift

Check 1-2 shift valve sticking in valve body. Spacer plate or gaskets damaged or not positioned properly. Case-
to-valve body face damaged or not flat. 2-4 servo assembly restricted or blocked case passages. Nicks or burrs
on servo pin or case pin bore. Missing or damaged piston or pin seals. 4th servo piston installed backward. 2-4
band worn or damaged, or band anchor pin not engaged. Check shift solenoids.

Slips In 1st Gear

Defective forward clutch assembly. Clutch plates worn. Piston porous or damaged. Piston seals missing or
damaged. Input housing-to-forward clutch housing "O" ring seal missing or damaged. Damaged housing.
Housing retainer and ball assembly damaged or not seating. Input shaft and housing assembly turbine shaft
seals missing or damaged. Accumulator valve stuck in valve body.

Valve body face not flat, damaged lands, or interconnected passages. Spacer plate or gaskets incorrect, damaged
or not positioned properly. Check for defective 1-2 accumulator piston assembly. Porosity in piston or cover
and pin assembly. Damaged piston ring grooves. Piston seal missing or damaged. Cover gasket missing or
damaged. Broken accumulator spring.

Incorrect oil pressure. Torque converter stator roller clutch not holding or 4th servo piston in backward.
Damage to low roller clutch lugs or inner ramps. Rollers not free moving, inadequate spring tension or damage
to inner splines. Oil passage plugged. Forward clutch accumulator piston seal missing or damaged. Piston out of
its bore. Stuck abuse valve.

Slipping Or Rough 1-2 Shift

Check for defective valve body assembly. 1-2 shift valve train or accumulator valve stuck. Gaskets or spacer
plate incorrect, damaged or not installed properly. Valve body face not flat.

Defective 2-4 servo assembly. Apply pin length incorrect. Servo seals or "O" ring seals missing or damaged.
Restricted or missing oil passages. Case servo bore damaged. Defective 2nd accumulator. Porosity in 1-2
accumulator housing or piston. Piston seal or groove damaged. Nicks or burrs in 1-2 accumulator housing.
Missing or restricted oil passages or 2-4 band worn or not positioned properly. Oil pump assembly or case faces
not flat.

Slipping, Rough Or No 2-3 Shift

Check for defective valve body assembly. 2-3 shift valve train or accumulator valve stuck. Gaskets or spacer
plate incorrect, damaged or not installed properly. Valve body face not flat.

Defective 2-4 servo assembly. Apply pin length incorrect. Servo seals or "O" ring seals missing or damaged.
Restricted or missing oil passages. Case servo bore damaged. Defective 2nd accumulator. Porosity in 1-2
accumulator housing or piston. Piston seal or groove damaged. Nicks or burrs in 1-2 accumulator housing.
Missing or restricted oil passages or 2-4 band worn or not positioned properly. Oil pump assembly or case faces
not flat.

1st & 4th Or 2nd & 3rd Gear Only

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Check shift solenoids for dirt, damaged seals or electrical connections.

3rd Gear Only

Check 2-3 shift solenoid and 3-2 control solenoid circuits, damaged seals or electrical connections.

3-2 Flare Or Tie Up

Check 3-2 control solenoid for dirt, damaged seals or electrical connections.

Slipping, Rough Or No 3-4 Shift

Check oil pump assembly faces not flat or pump cover retainer and ball assembly omitted or damaged. Valve
body assembly 2-3 shift train, accumulator valve, 1-2 shift valve or 3-2 control valve stuck. Manual valve link
bent or damaged. Spacer plate or gaskets incorrect, damaged or not positioned properly. Defective 2-4 servo
assembly.

Incorrect band apply pin. Servo seals missing or damaged. Porosity in pistons, cover or case. Plugged or
missing orifice cup plug. Case 3rd accumulator retainer and ball assembly leaking. Porosity in 3-4 accumulator
piston or bore. 3-4 accumulator piston seal or seal grooves damaged. Restricted oil passage. Defective input
housing assembly. Forward or 3-4 clutch plates worn, or excessive plate travel.

Forward or 3-4 piston seals damaged. Porosity in 3-4 clutch housing or piston. 3-4 piston check ball stuck,
damaged or not sealing. Restricted apply passages. Forward clutch piston retainer and ball assembly not seating.
2-4 band worn or not positioned properly. Sealing balls loose or missing.

No Reverse Or Slips In Reverse

Defective input housing assembly. 3-4 apply ring stuck in applied position. Forward clutch not releasing.
Turbine shaft seals missing or damaged. Manual valve link disconnected.

Defective valve body assembly. 2-3 shift valve stuck. Manual linkage out of adjustment. Spacer plate and
gaskets incorrect, damaged or not positioned properly. Defective reverse input clutch assembly. Clutch plate
worn. Housing and drum assembly cracked at weld. Clutch plate or return spring assembly retaining ring out of
groove. Piston deformed or dished.

Seals damaged or missing. Retainer and ball assembly not sealing. Restricted apply passage. Defective low-
reverse clutch. Clutch plates worn or retaining ring not positioned properly. Porosity in piston. Seals damaged.
Return spring assembly retaining ring not positioned properly. Case porosity. Case cover plate not tightened
properly or gasket missing or damaged.

No Part-Throttle Or Delayed Downshifts

Check for defective 2-4 servo assembly. Servo cover retaining ring missing or not assembled properly. 4th
apply piston damaged or not assembled properly. Inner housing damaged or not assembled properly. Defective
valve body assembly. 3-2 control valve stuck. 4-3 sequence valve body channel blocked. No. 5 check ball
missing.

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Harsh Garage Shifts

Check valve body for missing check ball, or orifice cup plug.

No Overrun Braking In Manual 3-2-1

Defective valve body assembly. 4-3 sequence valve or throttle valve stuck. No. 3 check ball not positioned
properly. Spacer plate and gaskets incorrect, damaged or not positioned properly. Defective input clutch
assembly. Turbine shaft oil passages plugged or not drilled. Turbine shaft seal rings damaged. Turbine shaft
sealing balls loose or missing. Porosity in forward or overrun clutch piston. Overrun piston seals damaged or
cut. Overrun piston check ball not sealing.

Drives (Creeps) In Neutral

Forward clutch not releasing. Manual valve link disconnected. Converter clutch apply valve stuck in oil pump.
Face of transmission case not flat or internal leakage in case.

Starts In 2nd In "D"

Forward sprag clutch assembly installed backward.

No Park

Parking linkage binding, loose, missing or not positioned properly.

Oil Pressure High Or Low

Oil pressure regulator valve stuck or valve spring damaged. Rotor guide omitted or not assembled properly.
Rotor cracked or reverse boost valve or sleeve stuck, damaged or not assembled properly. Orifice hole in
pressure regulator valve plugged. Sticking slide or excessive rotor clearance. Pressure relief ball not seated or
damaged. Pump cover or body has porosity. Incorrect pump cover or pump face not flat. Excessive rotor
clearance.

Intake pipe restricted by casting flash. Cracks in filter body or intake pipe. "O" ring seal missing, cut or
damaged. Incorrect lubricant used during rebuild procedure.

Manual valve scored or damaged. Spacer plate or gaskets incorrect, damaged or not assembled properly. Check
for stuck 2-3 shift valve, damaged pressure control solenoid or damaged pressure switch assembly. Check for
missing check balls or incorrect assembly. Case-to-valve body face not flat.

Harsh Shifts

Check PCM input signals from TP sensor, pressure switch assembly, fluid temperature sensor, VSS and engine
coolant temperature sensor. Inspect pressure control solenoid for damaged pins or seals, or dirt in oil circuits.

High Or Low Shift Points

Check for stuck pressure regulator valve or pump slide sticking. Spacer plate or gaskets damaged, incorrect or

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not assembled properly.

Valve body pad porous or damaged. 2-4 accumulator has porosity. Servo piston seals damaged. Apply pin
damaged or has improper length. 2-4 band burned or anchor pin not engaged. Throttle Position (TP) sensor,
VSS and/or 4WD low switch (if equipped) disconnected or damaged.

No Converter Clutch Apply

Transmission not supplied 12 volts. Outside electrical connector damaged. Inside electrical connector wiring
harness or solenoid damaged. Solenoid wire pinched. Solenoid not grounded. Pressure switches incorrect or
damaged. Temperature sensor damaged. Damaged engine speed sensor or pressure switch assembly. Converter
internal damage.

Converter clutch valve stuck or assembled backward, or retaining ring not positioned properly. Pump-to-case
gasket not positioned properly. Orifice cup plug restricted or damaged. Solenoid "O" ring seal cut or damaged.
Pump-to-body cover high or uneven bolt torque.Turbine shaft "O" ring seal cut or damaged. Turbine shaft
retainer and ball assembly restricted or damaged. TCC shift valve or apply valve stuck. Solenoid "O" ring
leaking. Solenoid screen is blocked.

Converter Shudder

Torque converter has internal damage. Converter clutch valve stuck. Restricted oil passages. Crack in filter
body. Restriction in filter neck. "O" ring seal cut or damaged. Turbine shaft "O" ring cut or damaged. Turbine
shaft retainer and ball assembly restricted or damaged. Low oil pressure. Engine not tuned properly.

No Converter Clutch Release

Solenoid external ground. Converter internal damage. Converter clutch valve stuck. Converter clutch apply
valve stuck in apply position. PCM external ground faulty.

Converter Clutch Applies When Cold

Check engine coolant temperature sensor and trouble codes.

Ratcheting Noise

Parking pawl return spring weak, damaged or not assembled properly.

Oil Leaking Out Vent

Chamber in pump body rotor pocket too large. Fluid level overfilled. Cross leak out of pump body and cover.

Vibration In Reverse & Whining Noise In Park

Broken oil pump vane rings.

Front Oil Leak

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Torque converter welded seam leaking. Damaged torque converter hub. Damaged front seal.

Pump Bushing Spins Out, "Walks" Into Seal, Or Seizes To Converter Hub

Transmission and engine center lines do not match. Excessive crankshaft runout. Bent flexplate (drive plate).
Excessive converter hub runout. Pump bushing I.D. not centered in pump. Bushing too loose in pump. Not
enough hub-to-bushing clearance.

Falls Out Of 4th Gear During Coasting

Low line pressure at idle (weak pressure regulator spring).

Binds Up On 3-4 Shift (Feels Like Brake Drag)

Forward pressure plate installed incorrectly. Too many plates in overrun clutch. Incorrect top steel plate
installed in overrun clutch.

No Forward Or Reverse Gears (Line Pressure Reading Okay)

Mismatched converter input shaft or broken turbine hub.

Binds Up In Reverse

Stator sleeve rotated out of position. Stuck2-3 shift valve. Servo pin jammed in case. Stuck 3-4 relay or 4-3
sequence valve.

No Drive In "D" Range

Torque converter stator roller clutch not holding.

No Drive In "OD" Range

Faulty output sprag. Teeth "hammered" out of forward friction plates.

CLUTCH & BAND APPLICATION

CLUTCH & BAND APPLICATION CHART

Shift Solenoid
Selector Lever Position Elements In Use
Position
"D" (Overdrive) First
1-2 ON/2-3 ON Forward Clutch, Forward Sprag & Low Roller Clutch
Gear
"D" (Overdrive) Second
1-2 OFF/2-3 ON Forward Clutch, Forward Sprag & 2-4 Band
Gear
"D" (Overdrive) Third
1-2 OFF/2-3 OFF Forward Clutch, Forward Sprag & 3-4 Clutch
Gear
"D" (Overdrive)
1-2 ON/2-3 OFF Forward Clutch, 2-4 Band & 3-4 Clutch
Overdrive

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

"D" (Drive) First Gear 1-2 ON/2-3 ON Forward Clutch, Forward Sprag & Low Roller Clutch
"D" (Drive) Second Gear 1-2 OFF/2-3 ON Forward Clutch, Forward Sprag & 2-4 Band
Forward Clutch, Forward Sprag, Overrun Clutch & 3-4
"D" (Drive) Third Gear 1-2 OFF/2-3 OFF
Clutch
"2" (Intermediate) First Forward Clutch, Forward Sprag, Low Roller Clutch &
1-2 ON/2-3 ON
Gear Overrun Clutch
"2" (Intermediate) Second Forward Clutch, Forward Sprag, Overrun Clutch & 2-4
1-2 OFF/2-3 ON
Gear Band
Forward Clutch, Forward Sprag, Low Reverse Clutch, Low
"1" (Low) First Gear 1-2 ON/2-3 ON
Roller Clutch & Overrun Clutch
"1" (Low) Second Gear Forward Clutch, Forward Sprag, Overrun Clutch & 2-4
(1) 1-2 OFF/2-3 ON
Band
"R" (Reverse) 1-2 ON/2-3 ON Low Reverse Clutch & Reverse Input Clutch
"P" (Park) 1-2 ON/2-3 ON Low Reverse Clutch
"N" (Neutral) 1-2 ON/2-3 ON All Clutches & Bands Released Or Ineffective
(1) Gear is only available above 30-35 MPH.

TORQUE CONVERTER

NOTE: Torque converter is a sealed unit and must be serviced as a complete

assembly.

INSPECTION

Torque converter must be replaced for any of the following reasons:

Damage To Pump Assembly

Metal Particles Present In Oil
Leaks In Hub Weld Area
Hub Scored Or Damaged
Stator Failure
Torque Converter Imbalance
Engine Coolant Contamination
Excessive End Play

STALL TEST

1. Torque converter whine is usually noticed when vehicle is stopped and transmission is in Reverse or
Drive. Whine will increase when engine RPM is increased and will stop when vehicle is moving or when
torque converter clutch is applied. Stall test is to ensure whine is coming from torque converter.
2. Start engine, and allow it to reach normal operating temperature. Apply parking and service brakes. Put
transmission in Drive. Depress accelerator to about 1200 RPM for less than 6 seconds. DO NOT depress

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

accelerator for more than 6 seconds or transmission damage may occur. Torque converter noise will
increase under this load.

NOTE: Torque converter whine should not be confused with pump whine, which is
usually noticeable in Park, Neutral and all other gear ranges. Pump whine will
vary with pressure.

STATOR CHECK

1. Torque converter stator roller clutch can either remain locked up at all times or freewheel in both
directions. If stator is freewheeling at all times, vehicle tends to have poor acceleration from a stop.
Vehicle may act normal at speeds above 30-35 MPH.
2. If poor acceleration is noted, ensure exhaust system is not blocked, engine timing is correct and
transmission is in 1st gear when starting from a stop. If stator is locked up at all times, performance from
a stop appears normal. Engine RPM and acceleration is limited at high speeds. Engine may overheat from
this condition.
3. A visual inspection of torque converter may reveal converter is Blue from overheating. If torque
converter has been removed from vehicle, stator roller clutch can be checked by inserting a finger into
splined inner race of roller clutch and trying to turn race in both directions. Inner race should turn freely
clockwise but should not turn or should be difficult to turn counterclockwise.

TORQUE CONVERTER END PLAY CHECK

1. Inspect torque converter for hub scoring, cracks or weld area cracks before checking end play. Install End
Play Checking Tool(J-35138) on torque converter. See Fig. 7 .
2. Note end play of torque converter. End play must be within specification. See TORQUE CONVERTER
END PLAY SPECIFICATIONS table. Replace torque converter if end play is not within specification
or damage to hub area exists.

TORQUE CONVERTER END PLAY SPECIFICATIONS

Converter Diameter: In. (mm) End Play: In. (mm)
9.65 (245.0) .0-.020 (.0-.51)
11.73 (298.0) .0-.024 (.0-.61)

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 7: Checking Torque Converter End Play

Courtesy of GENERAL MOTORS CORP.

ELECTRONIC SELF-DIAGNOSTICS & ELECTRONIC TESTING

NOTE: See AUTO TRANS DIAGNOSIS - 4L60-E article.

TESTING
ROAD TEST

NOTE: Shift speed charts reference throttle position angle instead of minimum or wide
open throttle position. This measurement is more accurate. A scan tool should
be used to monitor throttle position angle. For transmission model code, refer
to metal identification tag attached to transmission.

Gear Selector Position "D4" (Overdrive)

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

1. With gear selector in "D4" (overdrive) position, choose throttle position angle of 12 or 25 percent. See
Fig. 8 or Fig. 9 . Set scan tool to monitor throttle position angle and vehicle speed. Accelerate vehicle to
chosen throttle position angle and hold throttle steady.
2. Note shift speed engagement points in 2nd gear, 3rd gear and overdrive gear. Use charts as a reference for
proper shift speeds. See Fig. 8 or Fig. 9 . Also note Torque Converter Clutch (TCC) engagement point
while in overdrive. Repeat procedure using different throttle position angle.

NOTE: Shift speeds may vary due to slight hydraulic delays responding to
electronic controls. A change from original equipment tire size also affects
shift speeds. Ensure TCC engages in 3rd or overdrive. TCC should not
apply unless transmission has reached a minimum operating temperature
of 64°F (18°C) and engine coolant temperature is 140°F (60°C).

3. At vehicle speeds of 40-50 MPH in overdrive, quickly increase throttle position angle to more than 50
percent. Verify TCC releases, transmission immediately downshifts to 3rd gear and 1-2 shift solenoid
turns off.
4. At vehicle speeds of 40-50 MPH in overdrive, quickly depress accelerator to wide open position (full
throttle detent downshift). Verify TCC releases, transmission immediately downshifts to 2nd gear, 1-2
solenoid is off and 2-3 solenoid is on.
5. At vehicle speeds of 40-55 MPH in overdrive, release accelerator pedal while moving gear selector to
"D3" (third gear) position. Verify TCC releases, transmission immediately downshifts into 3rd gear, and
engine braking slows vehicle.
6. Move gear selector to "D4" (overdrive) position, and accelerate to 40-45 MPH. Release accelerator pedal
while moving gear selector to "D2" (2nd gear) position. Verify TCC releases, transmission immediately
downshifts to 2nd gear, and engine braking slows vehicle.
7. Move gear selector to "D4" (overdrive) position, and accelerate to 30 MPH. Release accelerator pedal
while moving gear selector to "D1" (1st gear) position. Verify TCC releases, transmission immediately
downshifts to 1st gear and engine braking slows vehicle.
8. With gear selector in the "D4" (overdrive) position, accelerate vehicle to overdrive gear with TCC
applied. Release accelerator pedal, and lightly apply brakes. Verify TCC releases and downshifts occur at
speeds shown in shift speed charts. See Fig. 8 or Fig. 9 .

NOTE: Upshifts in manual gear ranges are controlled by shift solenoids. Perform
following steps by accelerating vehicle at throttle position angle of 10-15
percent.

Gear Selector Position "D3" (3rd Gear)

With vehicle stopped, move gear selector to "D3" (3rd gear) position and steadily increase throttle pressure to
accelerate vehicle. Note speeds at which vehicle shifts into 2nd and 3rd gears. See Fig. 8 or Fig. 9 .

Gear Selector Position "D2" (2nd Gear)

With vehicle stopped, move gear selector to "D2" (2nd gear) position. Accelerate vehicle and note speed at
which vehicle shifts from 1st gear to 2nd gear. Accelerate vehicle to 35 MPH. Verify transmission does not shift

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

into 3rd gear, and TCC does not apply.

Gear Selector Position "D1" (1st Gear)

With vehicle stopped, move gear selector to "D1" (1st gear) position. Accelerate vehicle to 20 MPH. Verify
transmission does not upshift, and TCC does not apply.

Gear Selector Position "R" (Reverse)

With vehicle stopped, move gear selector to "R" (Reverse) position. Verify 1-2 and 2-3 shift solenoids are on.

SHIFT SPEED CHARTS

Fig. 8: Hydra-Matic 4L60-E Shift Speed Charts (1997)

Courtesy of GENERAL MOTORS CORP.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 9: Hydra-Matic 4L60-E Shift Speed Charts (1998)

Courtesy of GENERAL MOTORS CORP.

HYDRAULIC PRESSURE TEST

CAUTION: Parking and service brakes must be applied throughout hydraulic

pressure test. Total time for testing with vehicle in any driving gear should
not exceed 2 minutes. Transmission damage may occur.

1. Before performing hydraulic pressure test, check fluid level and condition. Check manual control
linkages for correct adjustment, and ensure engine is properly tuned.
2. Connect scan tool to Data Link Connector (DLC). Apply parking brake and start engine. Check for stored
trouble codes. If trouble codes are present, diagnose as necessary. See AUTO TRANS DIAGNOSIS
article. Turn engine off. Connect oil pressure gauge to line pressure test port. See Fig. 10 .
3. Start engine and warm to normal operating temperature. With vehicle in Reverse, line pressure should be
64-324 psi (441-2234 kPa). With vehicle in Park, Neutral or Drive, line pressure should be 55-189 psi
(379-1303 kPa).
4. Shift transaxle into Park. Access Pressure Control Solenoid (PCS) test on scan tool. Increase DESIRED
PCS in .1 amp increments and read corresponding line pressure on oil pressure gauge. Allow pressure to
stabilize for 5 seconds after each current change. Compare readings to LINE PRESSURE
SPECIFICATIONS . If pressure readings are not as specified, and no trouble codes are present, internal
malfunction exists. See TROUBLE SHOOTING .

NOTE: Scan tool is only able to control pressure control solenoid in Park and Neutral
with vehicle stopped. This protects clutches from extremely high or low

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

pressures in Reverse and Drive.

LINE PRESSURE SPECIFICATIONS

PCS Current (Amp) Line Pressure - psi (kPa)
.02 170-190 (1172-1310)
.10 165-185 (1137-1275)
.20 160-180 (1103-1241)
.30 155-175 (1068-1207)
.40 148-168 (1020-1158)
.50 140-160 (965-1103)
.60 130-145 (896-1000)
.70 110-130 (758-896)
.80 90-115 (621-793)
.90 65-90 (448-621)
.98 55-65 (379-448)

Fig. 10: Installing Oil Pressure Gauge

Courtesy of GENERAL MOTORS CORP.

REMOVAL & INSTALLATION

See TRANSMISSION REMOVAL & INSTALLATION - A/T article in the TRANSMISSION SERVICING
section.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

TRANSMISSION DISASSEMBLY

NOTE: Beginning at start of production for all 1996 models, some 4L60-E
transmissions were built with a bolt-on bellhousing. Design change will make
4L60-E transmission more versatile for a wide variety of engine sizes. Bolts
securing bellhousing require a Torx-Plus 50-IP bit for removal. Bolt heads will
strip if incorrect tool is used during removal. Transmission case has a totally
different casting design for bolt-on bellhousing. Oil pump body has a machined
ring added to front of pump body to center bellhousing on installation.

2-4 SERVO ASSEMBLY

1. Mount transmission on bench using Holding Fixture (J-8763-02). Remove torque converter. Install Servo
Cover Compressor (J-29714) on oil pan. See Fig. 6 . Compress servo cover. Remove retaining ring, servo
cover and "O" ring.
2. Remove 2-4 servo assembly. Servo pin length should be checked before disassembling assembly to
determine 2-4 band and reverse input drum wear or damage.

CHECKING SERVO PIN LENGTH

1. Remove 4th apply piston and return spring. See Fig. 11 . Remove retainer ring, washer, apply pin spring
and 2nd apply pin. Install Piston Compressor (J-22269-01) on 2nd apply piston. See Fig. 12 .
2. Remove retainer ring, cushion spring and spring retainer. Install Band Apply Pin Tool (J-33037) and
apply pin. See Fig. 13 . Apply 100 INCH lbs. (11 N.m) torque.
3. White line on band apply tool should be within gauge slot if pin length is correct. If White line is not
within gauge slot, inspect 2-4 band and reverse input drum for wear and damage during disassembly.
4. Servo pin length must be checked during reassembly. Servo pin is preset and must not be readjusted. See
SERVO PIN SPECIFICATIONS table under 2-4 BAND & SERVO ASSEMBLY under
TRANSMISSION REASSEMBLY.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 11: Exploded View Of 2-4 Servo Assembly

Courtesy of GENERAL MOTORS CORP.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 12: Compressing 2nd Apply Piston

Courtesy of GENERAL MOTORS CORP.

Fig. 13: Measuring Servo Pin Length

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Courtesy of GENERAL MOTORS CORP.

EXTENSION HOUSING

Remove speed sensor retaining bolt. Using Puller (J-38417), remove speed sensor assembly and "O" ring. See
Fig. 16 . Remove extension housing and seal. Remove output shaft sleeve and "O" ring (if equipped). Remove
speed sensor rotor from output shaft (if necessary). Install Gear Puller (J-21427-01) and Adapter (J-8433) on
rotor. Pull rotor from output shaft.

1-2 ACCUMULATOR & SPACER PLATES

1. Remove solenoid retaining bolts. Remove solenoid and "O" ring. Remove wiring harness, and note
location for reassembly reference. Carefully remove accumulator cover retaining bolts, 1-2 accumulator
cover and pin assembly. See Fig. 16 .
2. Remove 1-2 accumulator piston, seal and spring. Remove spacer plate, and note check ball and filter
locations. Remove spring, 3-4 accumulator piston and pin. Note spacer plate and gasket locations. See
Fig. 5 for check ball and filter locations.

TRANSMISSION END PLAY CHECK

NOTE: Check transmission end play before disassembly. If end play is not within
specification, check for damaged parts during disassembly.

Install Pump Remover/End Play Fixture (J-24773-A) and End Play Adapter (J-25022-A) on end of turbine
shaft. See Fig. 14 . Clamp dial indicator on long bolt with indicator tip on end play fixture. Zero dial indicator.
Pull up on end play fixture. Measure transmission end play. Transmission end play should be .005-.036" (.13-
.91 mm).

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 14: Checking Transmission End Play

Courtesy of GENERAL MOTORS CORP.

OIL PUMP, INPUT CLUTCH & REVERSE CLUTCH

1. Ensure TCC solenoid assembly and oil filter are removed before oil pump removal. Remove oil pump
retaining bolts. Using Oil Pump Remover (J-37789-A) and Adapter (J-39119), pull oil pump assembly
free from case. See Fig. 15 .
2. Remove oil pump, seal and gasket. Remove reverse input clutch-to-pump thrust washer from pump. Lift
out turbine shaft with reverse input clutch assembly.

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 15: Removing Oil Pump Assembly

Courtesy of GENERAL MOTORS CORP.

2-4 BAND & INPUT GEAR SET

1. Remove band anchor pin from case. See Fig. 16 . Remove 2-4 band assembly from case. Remove input
sun gear. See Fig. 17 .

CAUTION: Output shaft must be held in place when removing input carrier
retainer ring.

2. Install Output Shaft Support (J-29837) on output shaft. See Fig. 18 . Remove input carrier to output shaft
retainer ring. Remove input carrier. Remove output shaft. Remove input carrier thrust bearing from
reaction carrier shaft.

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Fig. 16: Exploded View Of 4L60-E Transmission External Components

Courtesy of GENERAL MOTORS CORP.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 17: Exploded View Of 4L60-E Transmission Internal Components

Courtesy of GENERAL MOTORS CORP.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 18: Installing Output Shaft Support

Courtesy of GENERAL MOTORS CORP.

REACTION GEAR SET

1. Remove input internal gear and reaction carrier shaft. Remove reaction sun shell and thrust washer.
Remove sun shell-to-clutch race thrust washer. Remove support-to-case snap ring.
2. Remove support retainer spring from low-reverse support. Remove reaction sun gear, low-reverse roller
clutch race, roller clutch, support assembly and reaction carrier assembly. See Fig. 17 .
3. Remove low-reverse clutch plates. Note locations of components. Remove internal reaction gear and
thrust bearing. Remove internal reaction gear support-to-case thrust bearing.

LOW-REVERSE CLUTCH

NOTE: Parking pawl may require removal to access low-reverse clutch.

1. Remove parking lock bracket retaining bolts. Remove lock bracket. Using screw extractor, remove shaft
plug. Remove parking pawl shaft, parking pawl and return spring if necessary. See Fig. 16 .
2. Using Clutch Spring Compressor (J-23327), compress low reverse clutch spring retainer. Remove spring
retaining ring and low-reverse spring assembly. Remove low-reverse clutch piston by applying air
pressure in case apply passage. See Fig. 19 .

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 19: Removing Low-Reverse Clutch Piston

Courtesy of GENERAL MOTORS CORP.

INNER MANUAL SHAFT LINKAGE

Remove manual shaft nut. Remove manual shaft and retainer. Remove parking lock actuator assembly and
inner detent lever. Remove manual shaft seal from transmission case. See Fig. 16 .

3RD ACCUMULATOR CHECK VALVE

1. Check 3rd accumulator check valve before removing it. DO NOT remove check valve unless it is leaking.
Install servo assembly in bore. Install servo cover and retaining ring. See Fig. 6 . Pour clean solvent in
bore. Inspect for leaks in transmission case. Replace check valve assembly if it leaks. See Fig. 20 .
Remove servo assembly.
2. For check valve removal, install No. 4 screw extractor in check valve assembly. Remove check valve.
Ensure bore is free of burrs. Installation tool must be made to ensure proper installation depth is obtained.
Using a 3/8" O.D. rod, scribe indicator mark at 1.653" (41.98 mm) from end of rod. Install check valve
until scribe mark on rod is flush with case. See Fig. 20 .

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 20: Installing 3rd Accumulator Check Valve Assembly

Courtesy of GENERAL MOTORS CORP.

CLEANING & INSPECTION

TRANSMISSION CASE

Cleaning & Inspection

Clean transmission case and dry with compressed air. Inspect case assembly for damage, cracks and damaged
bolt hole threads. Inspect valve body surface for flatness and land damage. Check case oil passages for

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restrictions and blockage. Inspect case internal clutch plate lugs for damage and wear. Inspect servo and
accumulator bores for damage. Inspect all snap ring grooves for damage.

CASE ATTACHMENTS

Cleaning & Inspection

Clean all parts and dry with compressed air. Inspect 1-2 and 3-4 accumulator parts for damage to pistons or
housing. Inspect for flatness and condition of accumulator, oil passage plate and gasket. Inspect wiring harness
leads and connectors for damage. Inspect speed sensor rotor teeth for damage and distortion.

REACTION & INPUT GEAR SETS, LOW-REVERSE CLUTCH & SUPPORT

Cleaning & Inspection

1. Clean all parts and dry with compressed air. Inspect reaction and input carriers for pinion gear damage,
excessive wear and improper staking of pinion pins. Inspect carrier bearings for heat damage, flatness and
roller condition. Place output shaft sleeve inside reaction carrier and input carrier.
2. Rotate sleeve and note smoothness of bearing operation. Replace carrier assembly if roughness is felt.
Check pinion gear end play on reaction and input carriers.
3. Pinion gear end play should be .008-.024" (.20-.61 mm). Inspect internal reaction gear and support for
cracks and damaged splines. Inspect low-reverse clutch plates for wear and signs of excessive heat.
4. Inspect low-reverse clutch piston for roughness or damage in seal ring area. Inspect retainer ring and
spring assembly for damage. Inspect sun and internal gears and supports for spline and bushing wear and
damage. Replace damaged parts as necessary.

COMPONENT DISASSEMBLY & REASSEMBLY

REVERSE INPUT CLUTCH

Disassembly

1. Remove snap ring from reverse input clutch housing. Remove selective backing plate, steel plates,
composition plates and Belleville plate. See Fig. 17 . Note number of clutch plates for reassembly
reference. Compress reverse input clutch spring assembly.
2. Remove retainer ring and spring assembly. Remove piston and seals. Thickness of composition plates
should be .068-.074" (1.73-1.88 mm). Thickness of steel plates should be .075-.081" (1.90-2.05 mm).
Thickness of Belleville plate should be .087-.091" (2.21-2.31 mm).

Inspection

Inspect all plates for damage, distortion, flatness and burred edges. Inspect spring retainer for distortion. Check
piston for deformation or damage. Inspect clutch housing bushings for wear. Inspect clutch housing for dishing.
Replace worn or damaged parts as necessary.

NOTE: Soak clutch plates in ATF before installation.

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Reassembly

1. Apply ATF to piston seals. Install seals on piston with seal lips facing away from plates. Install piston in
clutch housing. Install spring assembly with large opening toward piston. Compress spring assembly.
Install retainer ring.

CAUTION: Ensure correct retainer ring is used. Ensure reverse input clutch
retainer ring is not interchanged with low-reverse retainer ring.

2. Install Belleville plate. Install clutch plates starting with steel plate and alternating with composition
plate. Install backing plate with chamfered side upward. Install snap ring. Apply even pressure to backing
plate using fingers.
3. DO NOT apply too much pressure or Belleville plate will be distorted. Using feeler gauge, measure
clearance between snap ring and backing plate. Clearance should be .040-.076" (1.02-1.93 mm). Select
backing plate. See REVERSE INPUT CLUTCH BACKING PLATE SPECIFICATIONS table.

REVERSE INPUT CLUTCH BACKING PLATE SPECIFICATIONS

Identification Number Thickness In. (mm)
2 .285-.292 (7.24-7.42)
3 .257-.263 (6.53-6.68)
4 .228-.234 (5.79-5.94)

LOW-REVERSE SUPPORT ASSEMBLY

CAUTION: Note direction roller clutch is installed in support. Roller clutch must be
installed in proper direction to provide lockup of inner race when rotated.

Disassembly & Inspection

Remove inner race and snap ring. Remove roller clutch assembly. Check inner race for damage and surface
finish. See Fig. 21 . Inspect roller and springs for damage and distortion. Inspect support for loose cam, cracks
and damaged surface finish. Replace damaged parts as necessary.

Reassembly

1. Install roller clutch assembly in low-reverse support. See Fig. 21 . Place support in case with hub facing
downward. Install inner race. Rotate inner race while pushing downward. Use care not to damage roller
and springs during installation.
2. Ensure inner race is fully seated. Bottom tangs will be flush with carrier hub when fully seated. Inner race
should rotate clockwise and lock counterclockwise with clutch hub downward. Insert support retainer
spring into case between case lug and open notch in support.

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 21: Exploded View Of Low-Reverse Clutch Assembly

Courtesy of GENERAL MOTORS CORP.

INPUT CLUTCH & FORWARD CLUTCH HUB ASSEMBLY

Disassembly

1. Remove snap ring and backing plate. Remove 3-4 clutch plates. Note number and location of parts for
reassembly reference. Remove 3-4 apply plate and clutch ring retainer. See Fig. 17 .
2. Remove forward clutch snap ring, and remove backing plate. Remove forward clutch sprag assembly and

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bearing. Remove input housing seal. Remove forward clutch plates. Note number and location of parts for
reassembly reference. Remove waved and apply plates. Remove overrun clutch plates (2 steel and 2
composition). Compress overrun clutch spring retainer.
3. Remove snap ring and spring assembly. Remove overrun clutch piston and forward clutch piston.
Remove seals from pistons. Note direction of seals. Remove forward clutch housing. Remove 3-4 clutch
spring, 3-4 clutch apply ring and piston. Remove "O" ring from input housing. Remove turbine shaft oil
seal rings.
4. Remove forward clutch race. Remove snap ring and overrun clutch hub. Remove sprag retainer and race.
Note direction race is installed. Use care not to lose rollers from roller cage.

Inspection

1. Inspect sprag assembly for weak or damaged springs and retainers and worn rollers. Inspect overrun
clutch hub for spline damage, excessive wear and open oil passages. Inspect retainer and race for spline
damage, surface wear and damaged ring grooves.
2. Replace sprag assembly if damaged. Inspect forward clutch race for spline damage, excessive wear and
open oil passages. Inspect input shaft and housing for spline damage, wear and open feed passages.
3. Inspect 3 sealing check balls located in rear of turbine shaft for tightness. Turbine shaft contains one open
lubrication hole. Ensure orifice cup plug is installed. Inspect turbine shaft seal areas for roughness and
burrs.
4. Inspect check ball located in input housing for free operation. Inspect pistons for wear, damage and
porosity. Inspect spring assemblies for damage and distortion.
5. Inspect steel and composition plates for damage. Inspect snap rings for distortion and damage. Check
backing plates for flatness and distortion. Inspect clutch apply rings for distortion and damaged tangs.
6. Inspect forward clutch housing check ball for proper operation (if equipped). Inspect housing for cracks
and damage in seal areas. Inspect bearings for excessive wear, flatness, damage and flat rollers.

Reassembly

1. For input housing check ball replacement, drive retainer and ball assembly from housing using 1/4"
diameter drift. Install NEW check ball assembly using 1/4" drift. Check ball assembly should seat on
housing shoulder. Assemble forward clutch sprag assembly.
2. Install sprag assembly in forward clutch race. Notches located in sprag must face upward. See Fig. 22 .
Install snap ring on sprag retainer and race. Snap ring flange must face away from retainer and race.

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Fig. 22: Installing & Checking Forward Clutch Sprag Assembly

Courtesy of GENERAL MOTORS CORP.

3. Hold forward clutch race in left hand. Support sprag assembly. Install sprag retainer and race assembly in

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 1997 Isuzu Hombre S
1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

sprag assembly. See Fig. 17 . Rotate sprag retainer and race assembly counterclockwise. Install remaining
retainer ring. Install overrun clutch hub. Install snap ring.
4. Check sprag operation. Holding forward clutch race, rotate overrun clutch hub. Overrun clutch hub
should turn freely clockwise and lock counterclockwise. See Fig. 22 .
5. Place input clutch housing with turbine shaft downward. Install 3-4 piston seals with lips facing away
from hub. Install 3-4 piston in input housing.
6. Install 3-4 clutch apply ring. Install "O" ring seal in input clutch housing. Install forward clutch housing.
Install seals on forward clutch piston with lips facing away from tangs.
7. Install forward clutch piston in forward clutch housing. Install 3-4 spring on 3-4 clutch apply ring. Install
forward clutch assembly on3-4 spring assembly. Align forward clutch piston legs with tangs of3-4 apply
ring. Install Seal Protector (J-29883) on input housing.
8. Install 3-4 apply ring and forward clutch assembly in input clutch housing. Hold apply ring tangs while
installing. DO NOT allow forward clutch piston to separate from assembly. Ensure assembly is firmly
seated.
9. Install Seal Protector (J-29883) on input housing. Install overrun clutch piston with hub facing upward. If
fully seated, overrun piston should be 3/16" below top of snap ring groove in input housing hub. Install
spring assembly on overrun clutch piston. Compress springs, and install snap ring. Install input housing
seal.

NOTE: Soak clutch plates in ATF before installation. Coat all seals and "O" rings
with ATF. Coat thrust washers and bearings with petroleum jelly.

10. Install 4 overrun clutch plates, starting with steel plate. Align wide notches with case lugs. Install
remaining clutch plates, alternating steel and composition plates.
11. Install bearing assembly on input clutch hub. Bearing inner race must face input housing hub. Ensure
bearing is centered. Align clutch plate tabs. Install forward clutch sprag assembly in input housing. Align
overrun clutch hub with clutch plates.
12. Install forward clutch apply plate in input housing. Install forward clutch waved plate. Ensure all plates
are aligned with input housing tangs. Starting with steel plate, install clutch plates, alternating steel and
composition plates. Install backing plate and snap ring. See FORWARD CLUTCH PLATE
SPECIFICATIONS table.
13. Using 2 feeler gauges, measure clearance between backing plate and snap ring. Clearance should be .030-
.063" (.75-1.60 mm). Install proper size backing plate with chamfered side upward. See FORWARD
CLUTCH BACKING PLATE SPECIFICATIONS table. Install snap ring.
14. Install 3-4 clutch plates and backing plate. Install clutch plates and backing plate with chamfered side
upward. Install retainer ring. Using feeler gauge, measure clearance between backing plate and first
composition plate. Clearance should be .035-.083" (.89-2.11 mm).
15. Select proper backing plate to obtain correct clearance. See 3-4 BACKING PLATE
SPECIFICATIONS table. Air check all clutches at feed holes in turbine shaft.
16. During overrun clutch test, air pressure will blow past forward clutch piston seals and exit out forward
clutch feed hole in turbine shaft. Turbine shaft seals require sizing and should be installed just before oil
pump installation.

FORWARD CLUTCH PLATE SPECIFICATIONS

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1997-98 AUTOMATIC TRANSISSIONS Hydra-Matic 4L60-E Overhaul - Isuzu Hombre & S/T Series

Plate Type Quantity Thickness In. (mm)

Apply 1 .169 (4.29)
Backing 1 Selective
Composition 5 .070 (1.78)
Flat Steel 5 .090 (2.29)
Waved Steel 1 .070 (1.78)

FORWARD CLUTCH BACKING PLATE SPECIFICATIONS

Identification Letter Thickness In. (mm)
A .274-.278 (6.96-7.06)
B .250-.255 (6.35-6.48)
C .227-.232 (5.77-5.89)
D .205-.208 (5.21-5.28)
E .180-.185 (4.57-4.70)

3-4 CLUTCH PLATE SPECIFICATIONS

Plate Type Quantity Thickness In. (mm)
Backing 1 Selective
Composition 6 .079 (2.01)
Flat Steel (1) 1 .070 (1.78)
Flat Steel 5 .107 (2.71)
Stepped Apply 1 .220 (5.59)
(1) Same spline configuration as apply plate.

3-4 BACKING PLATE SPECIFICATIONS

Identification Thickness In. (mm)
A .224-.231 (5.69-5.87)
B .187-.196 (4.75-4.98)
C .153-.161 (3.89-4.09)

OIL PUMP ASSEMBLY

Disassembly

1. Remove reverse input clutch drum-to-oil pump thrust washer, pump-to-case gasket and pump-to-case oil
seal ring from pump assembly. Remove pump cover retaining bolts. Separate pump cover from pump
body.

CAUTION: Pump slide spring and pressure relief spring rivet are under high
pressure. To prevent possible injury, cover springs during removal.

2. Using needle-nose pliers, compress pump slide spring. Remove from pump by pulling straight out.

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Remove pump vane rings, pump vanes, pump rotor and rotor guide from pump pocket.

CAUTION: Keep pump vanes in installed position. If pump vanes are installed
upside-down or backwards, they will quickly wear out.

3. Remove slide from pump pocket. Remove slide seal and seal support from pump slide. See Fig. 23 .
Remove pivot pin and pivot pin spring. Remove seal ring and "O" ring from pump slide. Remove seal
retainer and seal from pump body.
4. Check condition of pump bushing. If bushing is in good condition, DO NOT remove it. Push inward on
converter clutch valve stop to compress spring. Remove snap ring. Remove valve stop, converter clutch
apply valve and springs.
5. Using a small punch, remove pressure relief spring retaining rivet. Remove relief spring and check ball.
Remove oil screen and "O" ring from pump cover. Remove reverse boost valve sleeve. Remove reverse
boost valve, pressure regulator valve spring and pressure regulator valve.

Fig. 23: Exploded View Of Oil Pump Assembly

Courtesy of GENERAL MOTORS CORP.

Inspection

1. Inspect all valves, springs, sleeves and bushings for chips, burrs, distortion and free movement in bores.
Check pressure relief check ball and spring for damage and distortion. Low line pressure will exist if
check ball and spring are damaged.
2. Inspect pump cover screen and "O" ring for wear and damage. Clean pump body and cover. Check all
bores for obstructions. Inspect mating sides of cover and body for scoring, flatness and damage between
channels. Check channels for dirt and damaged passages. Inspect stator shaft and pump body bushings for

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damage.
3. Inspect rotor and slide for scoring, cracks and damage. Check rotor guide and pump vane rings for
excessive wear and damage. Inspect all seals for damage. Measure pump rotor and slide thickness in
undamaged area if replacement is required. See OIL PUMP COMPONENT THICKNESS table. Ensure
replacement parts are matched to fit within specification.

OIL PUMP COMPONENT THICKNESS

Component In. (mm)
Pump Rotor & .7066-.7071 (17.948-17.960), .7071-.7076 (17.960-17.973), .7076-.7081 (17.973-
Slide 17.986), .7081-.7086 (17.976-17.998), .7086-.7091 (17.998-18.011)

Reassembly

1. Install "O" ring and seal ring in groove on back side of pump slide. Retain seal ring using petroleum jelly.
Install pivot pin and spring in pump body. Install pump slide. Notch in pump slide must align with pivot
pin hole and with flat oil seal ring facing downward in pump pocket. Install slide seal and support.

CAUTION: Keep pump vanes in installed position. If pump vanes are installed
upside-down or backwards, they will quickly wear out.

2. Install pump vane ring into pump pocket. Coat rotor guide with petroleum jelly. Install rotor guide on
rotor. Install rotor and guide into pump pocket with guide toward pump pocket. Install vanes in rotor.
Install vane guide ring. Compress pump slide spring and install into pump pocket. All parts must be even
with pump body surface. Install "O" ring on pump screen, and install screen in pump cover with "O" ring
end out.
3. Install oil seal in pump body. Install seal retainer. Install pressure relief check ball and spring in pump
cover. Install retaining rivet. Install converter clutch valve springs and converter clutch valve. Install
valve stop and snap ring. Install pressure regulator valve and spring in pump cover. See Fig. 23 .
4. Coat reverse boost valve with petroleum jelly. Install reverse boost valve in boost valve sleeve with small
end first. Install reverse boost valve sleeve in pump cover.
5. Install pump cover on pump body. Install retaining bolts finger tight. Align pump body and cover using
Alignment Strap (J-21368). Place bolt through pump-to-case bolt hole. Tighten retaining bolts to
specification. See TORQUE SPECIFICATIONS . Remove alignment strap.
6. Position pump-to-case gasket on pump, and retain it using petroleum jelly. Install oil seal rings on stator
hub. Retain oil seal rings using petroleum jelly. Install pump-to-case oil seal on cover. Ensure seal is not
twisted. Coat seal with ATF. Install pump-to-drum thrust washer. Ensure tangs on washer engage with
holes in hub.

2-4 SERVO ASSEMBLY

Disassembly

1. Remove 4th apply piston and housing from 2nd apply piston assembly. Remove return spring from apply
pin. Install Piston Compressor (J-22269-01) on 2nd apply piston. See Fig. 12 .
2. Compress 2nd servo apply piston assembly. Remove retainer ring. Separate 2nd apply piston, spring and

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retainer. Remove retainer ring, washer and spring from apply pin, and remove pin. Remove all oil seal
rings. See Fig. 11 .

Inspection

Inspect all pistons for porosity and damage. Check for ring groove damage and servo bore in case for any wear
which may cut servo seals. Check all springs and oil seal rings for distortion and damage.

Reassembly

Different servo piston housings and 2nd apply pistons are used for different applications. If servo piston
housing or 2nd apply piston is replaced, inside dimension of parts must be checked. Measure inside diameter of
piston housing and 2nd apply piston. Dimension must be same as original. To reassemble, reverse disassembly
procedure. Coat seals with petroleum jelly before assembly.

VALVE BODY

NOTE: Valves are held in valve body by pins or retainers. Valves may be under spring
pressure. Note location of all parts during disassembly for reassembly
reference.

Disassembly

Remove valve train, and note direction of valve installation. See Fig. 24 . Remove all valve pins, retainers and
bore plugs. Remove shift solenoids. Note locations of all parts.

Inspection

Inspect valves and sleeves for scoring and cracks. Ensure valves move freely in bores. Inspect valve body for
cracks and scored bores. Inspect machined surfaces for damage. Inspect springs for damaged coils. Replace
damaged parts as necessary.

Reassembly

For reassembly, reverse disassembly procedure. Ensure all parts are installed in correct location. See Fig. 24 .
Ensure pins, retainers and bore plugs are fully installed and do not extend into machined areas.

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Fig. 24: Exploded View Of Valve Body

Courtesy of GENERAL MOTORS CORP.

TRANSMISSION REASSEMBLY

NOTE: To identify bushing, seal, thrust bearing and thrust washer locations and
direction, see BUSHINGS, SEALS, BEARINGS & THRUST WASHERS . See Fig.
26 and Fig. 27 .

LOW-REVERSE CLUTCH

1. Place transmission in a vertical position. Install seals on low-reverse clutch piston. Apply petroleum jelly
to seals. Align and install piston with notch in bottom of transmission case. Ensure piston is fully seated
and parking pawl aligns with opening in piston wall. Install spring assembly with flat side of retainer
upward. Compress springs and install retainer ring.
2. Coat bearing assembly with petroleum jelly. Install bearing assembly on case hub with outside bearing
race toward case hub. Install internal reaction gear and support. Install bearing assembly onto support
with outside bearing race toward support. Install oil deflector (if equipped) and reaction carrier assembly
in case. See Fig. 17 . Ensure clutch plates are proper thickness.
3. Install clutch plates. See LOW-REVERSE CLUTCH PLATE USAGE table. Ensure clutch plates align
with splines of reaction carrier and case and that steel plates are aligned. Place waved plate on work
bench. Install 5 composition plates and 4 steel plates alternately, starting with composition plate.

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4. Install low-reverse support. Apply light pressure to low-reverse support. DO NOT flatten waved plate.
Measure height of clutch pack from work bench to top of low-reverse support. Using height dimension,
determine proper selective spacer plate to be used. See SPACER PLATE SELECTION table.
5. Place spacer plate between waved plate and first composition plate with identification facing upward.
Measure overall height of clutch pack. Overall height should be 1.15-1.18" (29.2-29.9 mm). Install clutch
pack assembly in transmission case.
6. Install low-reverse support in case with hub downward. Install inner race by pushing downward while
rotating until it is fully engaged. Bottom tangs will be flush with hub when fully installed. Install spring
retainer in case between case lug and open notch in support. Install low-reverse snap ring.

LOW-REVERSE CLUTCH PLATE USAGE

Type No. Used Thickness: In. (mm)
Composition 5 .089 (2.26)
Flat Steel 4 .069 (1.75)

SPACER PLATE SELECTION (1)

Measured Clutch Pack Height: In. (mm) (2) Plate Thickness: In. (mm)
1.084-1.105 (27.53-28.07) .066-.072 (1.67-1.85)
1.105-1.125 (28.07-28.58) .046-.052 (1.17-1.31)
1.064-1.084 (27.03-27.53) .087-.092 (2.19-2.34)
(1) Spacer plates are available in select sizes. Plate .066-.072" (1.67-1.85 mm) thick has no identifying
marks. Other plates are marked "0" or "1".
(2) Clutch pack height is measured without spacer plate in position.

REACTION & INPUT GEAR SETS

1. Install retainer ring on reaction sun gear (if removed). Install sun gear into reaction carrier. Install thrust
washer on low-reverse clutch race. Install reaction sun gear shell on reaction sun gear.
2. Install thrust washer on reaction sun gear shell. Ensure thrust washer tangs engage on gear shell. Install
input internal gear and reaction carrier shaft in sun gear shell. Carrier shaft splines must engage with
reaction carrier. See Fig. 17 .
3. Install thrust washer on reaction carrier shaft. Outer race must face toward reaction carrier shaft. Install
output shaft in transmission. Ensure output shaft engages with all parts.
4. Install Output Shaft Support (J-29837). Adjust support so output shaft is positioned upward as far as
possible. Install input carrier assembly with hub end down on output shaft. Install NEW retainer ring on
output shaft. Remove output shaft support. Install input sun gear, indexing gear end with input carrier
pinions.

REVERSE INPUT ASSEMBLY & INPUT CLUTCH

Install selective thrust washer on input housing. Install bearing assembly on selective thrust washer. Inner race
(Black) must go toward oil pump. Position reverse input assembly on input clutch assembly. Reverse input
clutch plates must align with input clutch hub. Ensure all clutch plates are fully engaged.

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REVERSE & INPUT CLUTCHES

Install reverse and input clutch assemblies in transmission case as an assembly. Align 3-4 clutch plates of input
assembly with input internal gear. Assembly is fully seated when reverse input clutch housing is just below oil
pump face of case.

2-4 BAND & SERVO ASSEMBLY

1. Install 2-4 band in case. Align band anchor pin end with case pin hole. Install band anchor pin in case.
Ensure band anchor pin aligns with end of 2-4 band.
2. Install 2-4 servo assembly into case, and index apply pin on band end. Check for proper engagement of
apply pin on band end. Recheck 2-4 servo apply pin selection to ensure correct pin is installed. See
CHECKING SERVO PIN LENGTH under TRANSMISSION DISASSEMBLY.
3. Different length servo pins are available. See SERVO PIN SPECIFICATIONS table. Select proper
length servo pin. Install servo cover and "O" ring. Compress cover and install cover retaining ring. Index
ring ends with slot in case.

SERVO PIN SPECIFICATIONS

Pin ID Pin Length - In. (mm)
1 Groove 2.59-2.60 (65.8-66.0)
2 Grooves 2.65-2.66 (67.3-67.5)
No Groove 2.70-2.71 (68.6-68.8)

BUSHINGS, SEALS, BEARINGS & THRUST WASHERS

NOTE: To identify bushing, seal, thrust bearing and thrust washer locations and
direction, see Fig. 26 and Fig. 27 .

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Fig. 25: Locating Oil Screens

Courtesy of GENERAL MOTORS CORP.

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Fig. 26: Location & Direction Of Transmission Oil Seals

Courtesy of GENERAL MOTORS CORP.

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Fig. 27: Location & Direction Of Transmission Bushings, Thrust Bearings & Thrust Washers
Courtesy of GENERAL MOTORS CORP.

OIL PUMP ASSEMBLY

1. Turbine shaft seals should be installed prior to oil pump installation. Position Seal Installer (J-36418-1)
on input shaft. See Fig. 28 . Adjustment screw in seal installer must be adjusted to obtain correct height
for each seal installation. Install 4 turbine shaft seals.

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Fig. 28: Installing & Sizing Turbine Shaft Seals

Courtesy of GENERAL MOTORS CORP.

2. Turbine shaft seals must be sized using Seal Sizer (J-36418-2A) after installation. Install aligning pins in
2 opposing pump bolt holes in case. Ensure thrust washer is installed on rear of oil pump. Thrust washer
can be retained using petroleum jelly.
3. Install oil pump into case, aligning filter and pressure regulator holes with holes in case. Install retaining
bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Place transmission in a
horizontal position.
4. Turbine shaft should rotate by hand. If turbine shaft will not rotate, loosen pump retaining bolts and
attempt to rotate shaft again. If shaft now turns, reverse and input assemblies have not been indexed
properly or some other assembly problem has occurred, such as thrust washer not positioned properly.
5. Check transmission end play. See TRANSMISSION END PLAY CHECK under TRANSMISSION

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DISASSEMBLY. Transmission end play should be .005-.036" (.13-.91 mm). If transmission end play is
not within specification, thrust washer must be changed between oil pump and input housing.
6. See OIL PUMP THRUST WASHER SPECIFICATIONS table. Install thrust washer, and recheck end
play. Install torque converter. Ensure converter hub is aligned with oil pump. Install torque converter
retaining strap to hold converter.

OIL PUMP THRUST WASHER SPECIFICATIONS

Identification Number Thickness In. (mm)
67 .074-.078 (1.88-1.98)
68 .080-.084 (2.03-2.13)
69 .087-.091 (2.21-2.31)
70 .094-.098 (2.39-2.49)
71 .100-.104 (2.54-2.64)
72 .107-.111 (2.72-2.82)
73 .113-.118 (2.87-3.00)
74 .120-.124 (3.05-3.15)

1-2 ACCUMULATOR & SPACER PLATES

CAUTION: If spacer plate and gasket replacement is required, ensure NEW spacer
plate and gasket are identical as those removed.

1. Install 3-4 accumulator piston pin in case. Install 3-4 piston seal on piston. Install 3-4 accumulator piston
on pin. Legs of piston must face valve body.
2. Install 3-4 accumulator spring. Install oil screens in proper locations. See Fig. 25 . Install special retainer
and ball assembly. See Fig. 5 for check ball and filter installation locations. Install spacer plate gasket and
spacer plate.
3. Install 1-2 accumulator spring, oil seal ring and 1-2 accumulator piston. Install accumulator cover and
bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

VALVE BODY

Install valve body. See VALVE BODY under ON-VEHICLE SERVICE .

EXTENSION HOUSING

1. Install speed sensor rotor retaining clip on output shaft. Install "O" ring in output shaft sleeve. Install
output shaft sleeve on output shaft. DO NOT position output sleeve past machined surface of output shaft.
Install seal ring on extension housing.
2. Position extension housing on transmission case. Install retaining bolts. Install oil seal in extension
housing. Install speed sensor assembly. Install retainer and bolt. Tighten bolt to specification. Install
outside electrical connector and manual shift lever.

TECHNICAL SERVICE BULLETINS

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1-2 &/OR 2-3 UPSHIFT SLIP/FLARE, NO 3RD OR 4TH GEAR,

(DTC P1870)

1996 GM Trucks & Oldsmobile Bravada With 4L60-E Transmission (GM Service Bulletin No. 66-71-03A)

Some owner's may complain that vehicle has either a slip or flare on 1-2 and/or 2-3 upshift, or no 3rd or 4th
gear. DTC P1870 may also be present. This condition may be caused by a poor internal ground between 2
circuit boards of Vehicle Control Module (VCM), which can cause VCM to command erratic line pressure at
pressure control solenoid. To correct this condition, a revised Wiring Harness (12167310) has been designed to
replace current wiring harness at VCM. Corrections were made to VCM beginning February 14, 1996.
Corrected VCM's are identified by service number 16244210, located on VCM identification label.

ATF LEAKING OUT VENT

All GM Models With 4L60 Or 4L60-E Transmission (ATRA TSB No. 449)

Vehicles equipped with 4L60 or 4L60-E transmission may leak fluid out transmission vent. Fluid may splash
out vent due to high fluid level. Fluid may also be pumped out due to an oil pump that is not flat or has been
machined, and now bolts are too long, allowing converter charge pressure to squeeze into vent cavity. To
correct this condition, check oil pump surface for flatness. Repair as necessary. Ensure both stator support pump
bolts and oil pump-to-case bolts are not too long. It may be necessary to add washers to bolts. Apply a thin
sealant to vent cavity surface area of oil pump and stator support, located between 9 and 10 o'clock position on
pump body. See Fig. 23 .

TRANSMISSION OVERHEATING &/OR CONVERTER DISCOLORED

All Models With 4L60-E Transmission

Transmission may show signs of overheating or torque converter is discolored. This condition may be caused
by regulated apply oil not available due to a TCC PCM solenoid filled with debris, which does not allow TCC
signal oil to lubricate TCC regulator apply valve in valve body. No DTCs are stored, as TCC PWM solenoid is
still working electronically. To eliminate the possibility of this condition, TCC regulator apply valve should be
machined to create 2 flat surfaces on opposite sides of first land on valve. Machined surface should be even
with wide head of valve. See No. 37 in Fig. Fig. 24 . Machining valve will completely bypass TCC regulator
apply valve, provide a more positive lock up apply feel and guarantee apply oil is always available.

DESIGN IMPROVEMENTS

1998 GM Vehicles With 4L60-E Transmission (ATRA TSB No. 458)

Manufacturer has made several design changes to 1998 4L60-E transmission. For improved drain back to
reduce aeration of fluid, transmission case has a larger cutout between 2 slots located above 1-2 accumulator
piston (at No. 1 check ball). See Fig. 5 . The 1998 design removed one slot to increase cutout size. A NEW
Black manual shaft has enhanced coating. Case extension housings are more rigid for improved durability.
Pressure Control Solenoid (PCS) has NEW design filter screen. Input sun gear to forward sprag inner race is a
press fit design. Transmission oil pan has a deep design with improved oil filter. Control valve body has a
chamfered edge for different dipstick stops. Dipstick stop has 2 different designs for regular or deep oil pan

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design.

OIL PUMP INTERCHANGE

NOTE: On GM vehicles with 4L60-E transmission, oil pump bodies have various
designs. Ensure components are not mismatched when pump components are
replaced.

1993-94

Pump body uses a 10 vane rotor and slide assembly. This pump body has the same casting and worm track
configuration as 1985-1993 models. Pump cover has a larger diameter filter seal bore.

1995-96

Pump body also uses a 10 vane rotor and slide assembly, but this pump body has a different casting and worm
track configuration than 1993-94 models and is not interchangeable. Pump body is identified by "PWM" cast
into front side of pump body. Bolt-on bellhousing also was introduced in 1996 and requires added flange to
center bellhousing during installation. Pump cover has a different casting and worm track configuration from
1993-94 models and is not interchangeable. Pump cover also includes "PWM" cast into back side of cover.

1997

Pump body has same worm track configuration as 1995-96 models, but a 13 vane rotor and slide assembly is
used. The 13 vane slide has longer porting slots. Pump body also has "PWM" cast into front side. Pump cover
has same worm track configuration as 1995-96 models, but porting slots are a different configuration from
1995-96 pump cover to accommodate changes in 13 vane and rotor and slide. Pump cover is identified by "13
V" cast into back side of pump cover. Pump cover is not interchangeable with other year models.

TRANSMISSION SPECIFICATIONS
TRANSMISSION SPECIFICATIONS
Application In. (mm)
Clearance
Forward Clutch .030-.063 (.75-1.60)
Reverse Input Clutch .040-.076 (1.02-1.93)
3-4 Clutch .035-.083 (.89-2.11)
End Play
Reaction & Input Planetary Pinion Gear .008-.024 (.20-.61)
Torque Converter
9.65" (245 mm) .0-.020 (.0-.51)
11.73" (298 mm) .0-.024 (.0-.61)
Transmission .005-.036 (.13-.91)
Height
Low-Reverse Clutch 1.15-1.18 (29.2-29.9)

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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Converter Housing Bolt 55 (75)
Cooler Pipe Connector 28 (38)
Detent Spring-To-Valve Body Bolt 18 (24)
Extension Housing Bolt 26 (35)
Fill Tube Bolt 35 (47)
Manual Shaft-To-Detent Lever Nut 23 (31)
Oil Pump Cover-To-Body Bolt 18 (24)
Oil Pump-To-Case Bolt 18 (24)
Park Bracket-To-Case Bolt 23 (31)
Torque Converter-To-Flexplate Bolt 46 (62)
Transmission-To-Engine Bolt 35 (47)
INCH Lbs. (N.m)
Accumulator Cover-To-Case Bolt 96 (11)
Line Pressure Plug 96 (11)
Oil Pan-To-Case Bolt 96 (11)
Oil Passage Cover Bolt 96 (11)
Pressure Switch Assembly 96 (11)
Solenoid Bolt 96 (11)
Speed Sensor Bolt 96 (11)
Valve Body-To-Case Bolt (1) 96 (11)
(1) Tighten valve body bolts in a spiral pattern starting in center of valve body.

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