4L60E Need to figure out a plan for rebuild.

[ODaily]

My 1993 SWB has the typical 4L60E failure, I've basically got R 1-2, and 3-4 are toast. Pretty typical really. I started to gather parts (without any plan) for a rebuild. Then life / money happened and I had to shelve it for a few months. Long story short, I'm back to looking at it, but I want to make a more organized effort in my rebuild planning, and I'd really appreciate some input.

My previous quasi plan was to gather most of the parts for a level 2 build from Sonnax.
https://www.sonnax.com/tech_resources/617-4l60e-performance-heavy-duty-transmission-build-charts


I have already acquired the following from the level 2 list:

Performance Pack HP-4L60E-01
SmartShell® Heavy Duty Reaction Shell Kit 77749-02K
Rear Stator Support Bushing 77002BT-01
Heavy Duty 2-3 Shift Valve 77754-41
Kevlar® Extra Wide Intermediate Band 77700-01K
Input Drum Reinforcement Kit 77733-51K
4th Gear Super Hold Servo 77767K

I also got the 2nd gear servo recommended for the level 3 build.
2nd Gear Super Hold Servo 77911-03K

I have not yet gotten...
Heavy Duty 3-4 Clutch Backing Plate Kit 74140-01K
because I was considering going all in on the level 3 with the custom input drum. I have since changed my mind, cause even level 2 is way overkill here for my application.


What I can think of that I still need:
Aluminum Pan
New Input Drum (for extra wide kevlar band)
Steels and clutches.
Gaskets.
Torque Converter.
Filter.
Solenoids.

What about upgrading planetary sets?

I should mention that I have a junkyard core that I plan to rebuild so as not to leave the truck stranded while I work on it.

What am I missing parts wise?

What about the wire harness? Should I try to find a new one?

Should I try and snag a master rebuild kit in addition to the parts listed, or try to find the stuff separately?

For a stock rebuild, I'd just grab an ATP kit, but I've already invested some cash in really good parts, and I want to keep that level of quality going. Are three better quality brands that I should look into?

Who makes NEW input drums? Sonnax only has their custom ones listed.

 

[ODaily]

And I forgot to mention this is a stock daily driver. With future dreams. The overkill build is to support anything I might dream up later.

 

[Erik the Awful]

When I emailed Sonnax to ask about my 700R4, they highly recommended getting high-friction steels and clutches.

 

[ODaily]

Everything I'm finding online is recommending Borg Warner Hi Energy clutches. I just can't find anyone that sells them. Especially as that's a vague-ish description.

A little digging later, it seems to be that the clutches are stock GM units for the 4l65E.

Is that correct? If so, anybody know a part # and/or a source?

 

[JWOK]

I used to order trans parts from Transtar and a quick google of the BW High Energy popped up a rebuild kit with the Transtar name. Might be worth a shot to look them up.

 

[ODaily]

Looks like Borg Warner puts out a clutch kit with the High Energy 3-4 clutches in it.
BorgWarner 34036KIT Friction Pack 4L60/E 87-UP w/High Energy 3/4 (.80)


Contains:
Borg Warner 30824AM Friction, Forward (.070")
Borg Warner 28455AM Friction, Overrun 4L60E
Borg Warner 27637AM Friction, 3-4 Clutch (.080")
Borg Warner 28831AM Friction, Low/Reverse
Borg Warner 26014AM Friction, Reverse Input

Sadly, no steels yet. Still looking.
If I can find the steels, then I should just need a basic rebuild kit???

Lots of sales BS out there. Kind of a mess to dig through.

 

[ODaily]

I used to order trans parts from Transtar

Did some digging on it. Looks like PN 74006EAF is the kit I need. Strangely, I don't know if I can order from Transtar directly. They have a location nearish me, or I might just phone call them. I can also find the kit online a few places. Thanks for the reference.

 

[Hamps]

If it is a daily driver this is what I have had really good luck with. I used this build in my suburban and I could not be more pleased. I used option A sonnax heavy duty truck build and also did the 2nd gear servo along with the 4th gear. I used a $250 rebuild kit from Amazon that literally had everything with 9 pack red clutches. For clearances I used .075 on the servo .045 on the 3-4 clutches and standards for everything else. I used the biggest Derale 19 row cooler with -6 AN fittings. It does whatever I want it to do and stays @ 150 degrees towing cruising with AC on. I did everything myself and it still cost around $800 but I could not be more pleased. I used a stock converter and run 275 tires with 3.73 gears. I have zero complaints.

 

[arrg]

This place will get you squared away. They'll even answer your questions on the phone.
https://probuiltautomatics.com/

 

[jaywestfall]

How timely, I'm getting ready to rebuild my L460E with similar stage, too. Sonnax is the way to go. I'm definitely going with the 5 pinion carriers!!!