Technical Service Information INTRODUCTION THM 4T60-E We wish to thank GENERAL MOTORS CORPORATION forthe information and illustrations that have made this booklet possible. This booklet contains general description and the overhaul procedures necessary to repair. overhaul, or service the new GENERAL MOTORS 4760-£ electronic overdrive automatic transaxle. ‘The THM 4T60-E is a fully automatic front wheel drive transaxle. It provides park, reverse, neutral, and four forward speeds including overdrive. ‘THE MAJOR COMPONENTS OF THIS UNIT ARE! * THREE BAND ASSEMBLIES (1) Forward Band (@) 1-2 Manual Band (@) Reverse Band * FOUR MULTIPLE DISK CLUTCH ASSEMBLIES (1) Input clutch (@) 2nd Clutch (8) 31d Clutch (4) 4th Clutch * THREE OVER-RUNNING CLUTCHES (1) Input Sprag 2) 3rd Roller Clutch @) 1-2 Roller Clutch * COMPOUND PLANETARY GEAR SET. * DIFFERENTIAL AND FINAL DRIVE ASSEMBLY ‘The shitt pattern is controlled electronically with solenoids that recieve ground signal fromthe PCM (Powertrain Control Module). The PCM will vary shift points, as it is constantly interpreting numerous electronic signals from various ‘operational sensors located on the vehicle. The PCM also controls application of the converter clutch and the TCC apply feet electronically with solenoids. Line pressure and shift feel are controlled by the vacuurn modulator system, This booklet contains Copyrighted Material reprinted with permission from Hydra-matic Div., GM Corp. ROBERT D. CHERRNAY DALE ENGLAND. TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL SUPERVISOR ED KRUSE PETE LUBAN LAYOUT TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 COPYRIGHT ATSG 1991, (305) 670-4161 1C4atTsc Technical Service Information AUTOMATIC TRANSMISSION SERVICE GROUP 2Technical Service Information 4T60-E CF-31) POWER FLOW CHART INPUT [SECOND [THIRD | FOURTH | FORWARD | D-2 [REVERSE] INPUT | 1-2 3RD CLUTCH [CLUTCH | CLUTCH | CLUTCH | BAND | BAND | BAND _| SPRAG | ROLLER | ROLLER wae D4/1ST ON D4/2ND ON ‘ON D4/3RD ON ‘D4/4TH ON ‘D3/1ST ON ‘D3/2ND ON D3/3RD ON D2/1sT ‘ON ‘D2/2ND ON ON, LO/1ST ‘ON T ‘ON mem T % APPLIED BUT NOT EFFECTIVE 4T60-E (F-31) SOLENOID PATTERN SHIFT SOLENOID SHIFT SOLENOID tat BY 1ST GEAR on on 2ND GEAR OFF on 3RD GEAR OFF OFF 4TH GEAR on OFF TCC APPLY SOLENOID THIS SOLENOID CONTROLS THE POSITION OF THE CONVERTER CLUTCH APPLY VALVE TCC PWM SOLENOID THIS SOLENOID CONTROLS CONVERTER CLUTCH APPLY FEEL AUTOMATIC TRANSMISSION SERVICE GROUP 3ATSG Technical Service Information 4T60 AND 4T60-E COMPARISON 4T60 C440-T4) VACUUM MODULATOR SYSTEM (CONTROLS LINE PRESSURE) T.V. CABLE SYSTEM GOVERNOR SYSTEM 28 VALVES IN VALVE BODY 1 SOLENOID 3 PRESSURE SWITCHES 1 ROLLER CLUTCH 1. SRD ROLLER CLUTCH 1 OVERRUNING SPRAG (INPUT) 4 CLUTCH PACKS 1. INPUT CLUTCH 2. SECOND CLUTCH 3. THIRD CLUTCH 4. FOURTH CLUTCH 1-2 BAND REVERSE BAND NONE NONE 1 PIECE TRANSAXLE CASE MACHINED IN CASE ACCUMULATORS (BOTTOM PAN) INPUT CLUTCH ACCUMULATOR IN CHANNEL PLATE 8 OIL PIPES 4T60-E CF~31) VACUUM MODULATOR SYSTEM (CONTROLS LINE PRESSURE) ELIMINATED ELIMINATED 14 VALVES IN VALVE BODY 4 SOLENOIDS 2 PRESSURE SWITCHES 2 ROLLER CLUTCHES 1. 3RD ROLLER CLUTCH 2. 1-2 ROLLER CLUTCH 1 OVERRUNING SPRAG (INPUT) 4 CLUTCH PACKS 1, INPUT CLUTCH 2. SECOND CLUTCH 3. THIRD CLUTCH 4. FOURTH CLUTCH FORWARD BAND REVERSE BAND MANUAL 1-2 BAND MANUAL 1-2 SERVO 2 PIECE TRANSAXLE CASE BOLT ON ACCUMULATORS (BOTTOM PAN) ELIMINATED (IT IS NOW THE 3-4 ACCUMULATOR) 4 OIL PIPES AUTOMATIC TRANSMISSION SERVICE GROUPPOWER FLOW CHART AND SHIFT SOLENOID PATTERN . WIRING SCHEMATICS ......00e0005 . OLL PASSAGE IDENTIFICATION ........seeeeeeeeesenee CHECK BALL LOCATIONS ......seseeeeeeeeeee TRANSAXLE DISASSEMBLY COMPONENT REBUILD ......seeceeeeeeeeees TRANSAXLE ASSEMBLY ......cesececssssrseeeeeeeees MODEL IDENTIFICATION ...sseseceeeseeeeeeeeseeeees VALVE BODY... ..es0+ SOLENOID SCREEN LOCATION .....ssssseeeeseeeeereees ELECTRICAL COMPONENTS ......606ssesesseseeeeeeees 96 TORQUE SPECIFICATIONS ....e.eceseseeeeeeeeseeeee 101 “This publication contains copyright material of General Motors Corporation and Hydra-Matle Division, General Motors Corporation. Itis reprinted with the permission of the copyright owner.” Information and part numbers contained in this handbook have been carefully compiled from industry sources known for their reliability, but ATSG does not guarantee its accuracy AUTOMATIC TRANSMISSION SERVICE GROUP RAR AARR RE a RnC4ATSG Technical Service Information CONDUIT TO BE POSITIONED TO WITHIN 4T60-E BUICK eet 60.0mm OF CONNECTOR AND CADILLAG weeNES. MEM, SOLENOID BRAKE SWITCH "8" SOLENOID eoet FTO "a" LENOIO NEGATIVE LINE EX To pce SLE) SOLENOID POSITIVE {COLOR 10-RED) CONNECTOR “A SOLENOID LINE G TO “8” SOLENOID NEGATIVE LINE B TO PWM. (COLOR 1D-GREEN) SOLENOID NEGATIVE (COLOR 10-WHITE) LINE EZ TO_PWM. SOLENOID POSITIVE (COLOR 10-RED) LINE EY TO “B" SOLENOID POSITIVE (COLOR ID-RED) LINEA TO TCC SOLENOID POSITIVE (COLOR I0-RED) UNE D TO T.CCivce, SOLENOID NEGATIVE (COLOR 1D-BLACK) LINE A POSITIVE WIRE x UNE eae NEGATIVE WIRE (COLOR 1D-8LACK) O-RING SEAL ‘SOLENOID ASM, Figure 1 AUTOMATIC TRANSMISSION SERVICE GROUP 6Technical Service Information CONNECTOR LINE A To T.CCuvEc. SOLENOID POSITIVE (COLOR 10-RED) LINE A POSITIVE WIRE CONDUIT TO BE POSITIONED TO WITHIN 4T60-E CHEVROLET 0.0mm OF CONNECTOR qecwvee, SOLENOID RAKE SWITCH 0 oiscreve. SWING) LINE F TO “A” SOLENOID NEGATIVE LINE EX TO a" (COL Ie BLJE! SOLENOID Positive | “H] im (CoLgRIo-RES) | et | PRESSURE SW (NO) “A” SOLENOID LO DISCRETE LINE G TO “8” ‘SOLENOID NEGATIVE (COLOR 10-GREEN) LINE EY TO “8” SOLENOID POSITIVE (COLOR 10-RED) LINE ¢ TO. LO DISCRETE SW (COLOR ID-BLACK) PRESSURE SW (N.O.) 4TH CLUTCH DISCRETE: LINE B TO. 4TH CLUTCH SW (COLOR ID-GREEN) LINE D TO TCC IVC ‘SOLENOID NEGATIVE (COLOR ID-BLACK) ; UNE D (COLOR \O-RED) _NEGATIVE WIRE ——~ (COLOR 1D-8LACK) ea ASSEMBLE TERMINAL WITH WIRE IN THE DOWNWARD POSITION SOLENOID ASM, AS SHOWN Figure 2 AUTOMATIC TRANSMISSION SERVICE GROUP 750 VoIo PASSAGES 1 SUCTION PUMP_PASSAGES Figure 4 AUTOMATIC TRANSMISSION SERVICE GROUPATSG Technical Service Information 2 UNE 38 4H 45 0 50 VOID PUMP PASSAGES Figure 5 517. 51 518 a, 533 8 27 4 ° ° 3 B18 sa s20st8 SLeeve, STEEL CONVERTER. Appw 8 © CONVERTER SEAL. ORAINBACK 5 CONVERTER RELEASE 7 SHAFT ASSEMBLY. Olt PUMP ORIVE 516 '3 RING, TURBINE SHAFT TO SUPPORT OIL SEAL RING. TURBINE SHAFT TO ORIVE SPROCKET (SNAP) 8 SPROCKET. ORIVE 5 WASHER, THRUST (ORIVE SPROCKET/SUPPORT? 318 Swart. TURBINE 319 RING, TURGINE SHAFT TO SUPPORT OIL SEAL 520 SEAL, O-RING (TURBINE SHAFT/HUB) GREEN 521 BEARING ASSEMBLY, ORIVE SUPPORT/SPROCKET (naw CUP) 522 SUPPORT, OnIvE spROcKET 523 BUSHING, DRIVE SPROCKET $1 Figure 6 AUTOMATIC TRANSMISSION SERVICE GROUP 9Technical Service Information 1 SUCTION 2 UNE 11 CONVERTER FEED 12 REGULATED APPLY 17 DECREASE 18 04 19 ORIVE SERVO APPLY 26 2NO 30 3R0 38 4TH 45 0 49 ExnausT 50 voIo VALVE BODY PASSAGES - OIL PUMP SIDE Figure 7 AUTOMATIC TRANSMISSION SERVICE GROUP 10Technical Service Information 1 suction UNE. 2 3 PRN 4 SoLeno1o 5 SOLENOID 6 7 8 INPUT CLUTCH FEED. INPUT CLUTCH PWM FEED 9 PWM 0 MOD 11 CONVERTER FEED REGULATED APPLY nies il ag A813 VALVE BODY PASSAGES - CHANNEL PLATE SIDE 18 04 18 DRIVE SERVO APPLY 20 SERVO APPLY 21 AUX INPUT CLUTCH FEED 22 PRIMARY TRIM: 23 1-2 accuM 24 233 Accum 26 34 ACCUM 26 2No 27 2NO/2NO EXHAUST 28 2No cLuTcH. 29 SOLENOID “8” OFF 30 3Ro 31 3RD/QRO EXHAUST 32 3RD CLUTCH 33 3RO CLUTCHILO-1ST 3a Tee Siawal 35 TCC ACCUM FEED ‘TCC ACCUM FEED BLOW OFF 37 ToC RELEASE an 40 4tH cluTCH 414TH CLUTCH EXHAUST 43 02 ‘44 MANUAL 2-1 SERVO 45 Lo 46 Lost 47 Reverse 49 REVERSE SeAVO 49 EXHAUST 50 voIo Figure 8 AUTOMATIC TRANSMISSION SERVICE GROUP u02827 Te 281240 O a @ [+ ° oS 7 1 suction 20 SERVO Ape 39 ¢THW/aTH EXHAUST 2 UNE 2) AUX INPUT CLUTCH FEED 4 atm cluTeH 3 PRN 22 PRIMARY TRIM 41 nw CLUTCH exnausT 4 SoLENoI 23 1-2 ACCUM 42 03 5 SOLENOIO “a 24 23 accuM 43 02 6 INPUT CLUTCH FEED 25 3.4 ACCUM 44 MANUAL 2-1 SERVO 7 iweur cuuTcH 28 2No. 45 Lo Pw FEED 27 2ND/2NO exnausT 46 Lo.ist 9 PWM 28 2no cuurcH 47 REVERSE 10 Moo 29 SOLENOID "8" OFF 48 REVERSE SERVO 1) CONVERTER FEED 30 30 49 EXHAUST 12 REGULATED APPLY 31 3RD/aRo exhaust 50 vo 13 RELEASE 32 3RO CLUTCH 14 appUy 33 3R0 CLuTcHiLo«sT OMITTED WHEN USING A PWM & 18 Cooter 34 TCC SIGNAL ‘FEC SOLENOIO. 16 Lu8e 438 ToC ACCUM Feo : cainTeS AEN eon csi 17 DECREASE 36 TCC ACCUM FEED BLOW OFF eae tue 18 be 37 TCC RELEASE 19 ORIVE SERVO APRLY 3a 4mm TYPICAL SPACER PLATE Figure 9 AUTOMATIC TRANSMISSION SERVICE GROUP 2Technical Service Information CHANNEL PLATE PASSAGES - VALVE BODY SIDE ¥ SUCTION 19 04 38 Tec AccUM FEED 2 UNE 18 ORIVE SERVO APPLY 436 TCC ACCUM FEED BLOW OFF 3 Paw 20 SERVO APPLY 37 TCC RELEASE 4 SoLeNoIo “8” 21 AUX INPUT CLUTCH FEED 38 5 BUSHING, GIFFERENTIAL TO CASE the case bore (See Figure 89). 3 CONNECTOR. ELECTRICAL (7 WAY] ° 38 Sex Sane 7. Install parking linkage if removed. 39 VENT ASSeMOLY, TRANSMISSION (See Figure 52). 100 ,FATER ASSEMBLY, TRANSMISSION OR Install new manual shaft seal, and tap 808 SEAL, MANUAL SHAFT down with a 15mm deep socket. —— 9, Install the final drive ring gear into ae the lugs in the case 10, Install final drive ring gear snap ring SE Sey into case groove, with the open end of CASE ASSEMBLY the snap ring to the opening in case. 1, Clean case thoroughly with solvent and (See Figure 90). dry case with compressed air. 11, Rotate transaxle to install final drive. 2. Inspect case for the following: * Lug damage. * Snap ring groove for damage. % Servo bores for wear or damage. ® Porisity in case casting. Stripped threads in bolt holes. 3. Install the drive sprocket support and torque bolts to 20 ft. lbs. 4, Install new converter seal with seal driver No. J-28540. 5. Lubricate converter seal inner surface with petrolatum. AUTOMATIC TRANSMISSION SERVICE GROUP 59.ATSG Technical Service Information 6, Install final drive thrust bearing onto final drive, (Black Side Up) and retain with petrolatum. 7, Install final drive assembly into transaxle, by rotating until it is engaged in ring gear and sun gear. 8. Install the final drive housing onto transaxle without the "0" ring, and use only 2 bolts to retain it, as we must remove it later on. We need it in place now to hold final drive. 9. Install dial indicator with the tools shown in Figure 92, and set to zero. 10. Lift speed sensor rotor with large screwdriver to check final drive end play, as shown in Figure 92. 11, Protect the speed sensor bore with a piece of vacuum hose on screwdriver. (See Figure 92). 12, Final drive end play should be .005"- 025", 13. Change final drive selective thrust washer as necessary to obtain this dimension. 14, Remove the dial indicator set-up and install J-38358 and J-26958, along with adapter J-26958-10, as shown in Figure 94. 15. Turn the loading tool adjusting knob until all final drive end play has been removed. 16. Rotate transaxle to position shown in Figure 95. 17. Make sure that final drive sun gear shaft is fully installed into the park gear and sun gear. 18. Install the forward band assembly in the case making sure it is engaged on the band anchor. 19, Install the thrust bearing onto the final drive ring gear, with the black side facing up (See Figure 95). Case TeaceuissOT . SAS Ascewout sormano TN SHAR Arnal Onive SUN GEAR Figure 95 AUTOMATIC TRANSMISSION SERVICE GROUP 61Technical Service Information 872, 738005 PINION END PLAY 0.23-0.61mm 1,009". (026°). CHECK WITH FEELER GAGE 572 CARRIER ASSEMBLY, INPUT 875 CARRIER ASSEMBLY. REACTION Figure 97 3 CASE, TRANSMISSION 677 BUSMING, REACTION SUN GEAR (LEFT HANO} 878 GEAR. OFUM BUSHING ASSEMBLY. REACTION SUN 879 BUSHING, REACTION SUN GEAR IRIGHT HANOI 880 SAND ASSEMBLY. 2/1 RACE, 1/2 SUPPORT (INNER) RING. SNAP (1/2 ROLLER ASSEMBLY) ROLLER ASSEMBLY, 1/2 SUPPORT SPACER. 1/2 SUPPORT. 888 SEARING ASSEMBLY, THRUST ASSEMBLY: ce 688 BUSHING, 1/2 SUPPORT 87 RACE, 1/2 SUPPORT (OUTER igure 96 1-2 ROLLER CLUTCH AND SUPPORT ASSEMBLY 1. Using tool J-38385, as shown in Figure 96, install the 1-2 roller clutch and support by lowering into the case. : 2. CAUTION: The 1-2 roller clutch/support | 4.3 SASE, TRANSMISSION assembly does not ALWAYS go all the way | $91 SeanING ASSEMBLY, THAUST down. Lift up on the forward band just | $72 CARRIER ASSEMBLY, INruT CommeTs SAM INPUT CARRIER TO REACTION CARRIER enough to let the support fall all the | 74 searing asséwavt: THRUST INPUT! eavadowy cal the beste, 75 CARRIER ASSEMBLY, REACTION COMPLETE 3. Install the 2-1 manual band into case, | $76 staring ASSEMBLY, THRUST REACTION CARRIER ensuring that it is located on the band SUN'GeAA anchor pin. 4, Install the reaction sun gear and drum assenbly, by rotating into position. a ed id if Figure 98 The lugs MUST engage with the 1-2 roller clutch inner race. 5. The reaction sun gear and drum should freewheel counterclockwise, and lock and turn forward drum clockwise. AUTOMATIC TRANSMISSION SERVICE GROUP oTechnical Service Information ASSEMBLE GEAR TRAIN 1, Inspect both input and the reaction carriers for wear or damage (See Figure 98). 2. Check for excess pinion gear end play with a feeler gage (See Fig- ure 97). 3. Proper pinion gear end play should be .009"'-.024". 4, Install the plastic lube dam into the input carrier inner bore 5. Install thrust bearing (674) onto input carrier, as shown in Figure 98, and retain with petrolatum. 6. Install reaction carrier into the input carrier by rotating into position. 7. Install thrust bearing (676) into reaction carrier, as shown in Fig- ure 98, and retain with petrolatum. 8. Thrust bearing (671) in Figure 98, is a "Trapped" bearing, and cannot be removed. 9. Install both carrier assemblys at the same time by rotating into position, ensuring that the reac- tion carrier is engaged onto the splines of the final drive sun gear shaft 10. Install the reverse reaction drum onto the input carrier and ensure that it is engaged on the splines. 13 FORWARD SERVO COVER 14 FORWARD SERVO COVER "0" RING SEAL. 15 FORWARD SERVO PIN "E" CLIP 16 FORWARD SERVO PISTON 17 FORWARD SERVO SPRING RETAINER 18 FORWARD SERVO PISTON "LIP" SEAL 19 FORWARD SERVO CUSHION SPRING 20 FORWARD SERVO CUSHION SPRING RETAINER 21 FORWARD BAND APPLY PIN 22 FORWARD SERVO RETURN SPRING 104 MANUAL 2-1 SERVO COVER 105 FORWARD SERVO SQUARE CUT SEAL 124 FORWARD SERVO APPLY PIPE 687 1-2 ROLLER CLUTCH SUPPORT ASSEMBLY 688 FORWARD BAND ASSEMBLY ee Figure 99 AUTOMATIC TRANSMISSION SERVICE GROUP 8