SECTION 7C - HYDRA-MATIC 4L60-E

AUTOMATIC TRANSMISSION

IMPORTANT

Before p erf orming any Service Operatio n o r oth er pro cedu re describ ed in th is Sectio n, refer t o Sect ion 00

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

1. GENERAL INFORMATION

SPACER PLATE AND GASKETS

1.1 MY2003 TRANSMISSION

TRANSMISSION IDENTIFICATION – MY2003

PRESSURE CONTROL SOLENOID

BOOST VALVE BUSHING

1.2 ‘HAD’ MODEL TRANSMISSION

3-4 CLUTCH

2. ELECTRICAL DIAGNOSIS

3. HYDRAULIC/MECHANICAL DIAGNOSIS

3.1 LINE PRESSURE CHECK

PRELIMINARY INFORMATION

PROCEDURE

4. ON-VEHICLE SERVICING

4.1 COOLER PIPE QUICK-CONNECT FITTING

REMOVE

REINSTALL

5. UNIT REPAIR

6. SPECIAL TOOLS

Techline

1. GENERAL I NFORMATION

The Hydra-Matic 4L60-E automatic transmission fitted to V2 Series Models carries over from VX Series I Models,

noting the following:

• Effective from a Julian build date (refer to Figure 7C1-2), of ‘1HND002 A 0000001’, the Torque Converter

Clutch ( TCC) Regulator Valve exhaust por t was reduced in s ize. T his change has m eant that, not only has the

control valve body changed but the spacer plate and both gas kets have also been m odif ied. The ear ly and later

gaskets and spacer plates can be physically identified as shown in Figure 7C-1.

• With the introduction of the Model Year 2003 Hydra-Matic 4L60-E automatic transmission into V2 Series Models

during O ctober 2002, the press ure control solenoid and boos t valve bushing were revised. As the design of the

wiring harness connec tor for the pr essure contr ol solenoid is also new, the internal trans mis sion wiring harness

also changes.

• With the introduction of the Model Year 2003 Hydra-Matic 4L60-E automatic transmission into V2 Series Models

during October 2002, new quick-connect fittings have replaced the flare nut fittings where the transmission

cooler pipes connect to the radiator and transmission.

• A new HAD (heavy duty) transmission was introduced into V2 Series Models fitted with the GEN III V8 engine

during October 2002.

Apart fr om the inf orm ation regarding the identific ation of the early and late type control valve body spac er plate and

gasket, the general information provided in this Section only applies to the MY2003 transmissions introduced into

V2 Series Models during October 2002. For the general information relating to the Hydra-Matic 4L60-E automatic

transmissions fitted to V2 Series Models not covered in this Section, refer to Section 7C1 – HYDRA-MATIC 4L60-E

AUTOMATIC TRANSMISSION – GENERAL INFORMATION, in the VX Series I Service Information.

SPACER PLATE AND GASKETS

Control Valve Body Gaskets Control Valve Body Spacer Plate

A B

C D

Figure 7C-1

Legend:

A. Pre-Change Gaskets – ‘V’ is the Valve body side, ‘C’ is the Case Gasket

B. Pre-Change Spacer Plate – Identification in an embossed ‘TJ’

C. Post-Change Gaskets – ‘VB’ is the Valve body side, ‘CA’ is the Case Gasket

D. Post-Change Spacer Plate – Identification in an embossed ‘1TJ’

Techline

1.1 MY2003 TRANSMISSION

With the introduction of the MY2003 release of the 4L60-E automatic transmission into V2 Series Models, the

following changes have been effected;

• The pressure control solenoid was revised.

• The boost valve bushing was revised.

• As the design of the wiring harness connector for the pressure control solenoid is also new, the internal

transmission wiring harness also changes

TRANSMISSION IDENTIFICATION – MY2003

The 4L60-E automatic tr ansm iss ion application and

identification can be determined from the stamping

in the rear of the transmission case, in the location

shown (7).

The coded number can be interpreted from the

following breakdown;

Model Year (‘3’ = 2003)

2. Model:

3.8 litre V6 S/C (L67)............... HN

5.7 litre GEN III V8 (LS1) ........ HA

3. Transmission Model Identifier (‘D’ = 4L60-E)

4. Julian Date (Day of the Year)

5. Shift Build ‘A’, ‘B’, ‘J’ = First Shift;

‘C’, ‘H’, ‘W’ = Second Shift

6. Individual Transmission Serial Number

Figure 7C-2

PRESSURE CONTROL SOLENOID (PCS)

The Pressure Control Solenoid (PCS) is a new

design.

As the design of the terminal connection is also

new, the internal transmission wiring harness also

changes.

With the change in the PCS, a change has been

effected in the line pressure that means a change

in the pressure checking procedure and results.

Refer to 3.1 LINE PRESSURE CHECK in this

Section for specific details.

Figure 7C-3

BOOST VALVE BUSHING

The orifice size (‘A’) in the boost valve sleeve,

(mounted in the oil pump housing) has been

reduced from a nominal 1.08 mm to 0.89 mm

(+0.07 mm/–0.06 mm), which affects the ATF

pressure boost characteristics of the valve.

Apart from this changed dimension, the bushing

has a new part number and has yellow dye applied

to it, for identification purposes.

Figure 7C-4

1.2 ‘HAD’ MODEL TRANSMISSION

To increase durability of the 4L60-E autom atic transm ission f itted to the GEN III V8 engine, the number of plates in

the 3-4 clutch pac k has been increas ed f r om six to s even plates. F or identification purposes , the transmission pref ix

has been changed from ‘HPD’ to ‘HAD’.

3-4 CLUTCH

The number of plates in the 3-4 clutch pack has been increased from six to seven plates. To achieve this result

without undergoing major internal component changes, the plates are thinner. This means that the same selective

plates can be used to achieve the same end float specification.

Apart from the change in part number, the HAD clutch plates can be physically identified by;

Composition plates – Thickness of new plates (1.62 ± 0.10 mm) and by one or more lightly coloured stripes

across the friction surfaces.

Steel plates – Thickness of new plates (2.42 +0.08 –0.07 mm).

2. ELECTRICAL DIAGNOSIS

The information regarding the electrical diagnosis of the automatic transmission as fitted to V2 Series Models

carries over from the information provided for VX Series Models, noting the following:

• Although there has been a revised pressure control solenoid wiring harness connector introduced with the

MY2003 automatic transmissions, the internal transmission harness layout remains unchanged.

For information relating to the electrical diagnosis of the Hydra-Matic 4L60-E automatic transmission fitted to V2

Series Models, refer to Section 7C2 – HYDRA-MATIC 4L60-E AUTOMATIC TRANSMISSION – ELECTRICAL

DIAGNOSIS, in the VX Series Service Information.

3. HYDRAULI C/ MECHANI CAL DIAGNOSIS

The information regarding the hydraulic/mechanical diagnosis of the automatic transmission as fitted to V2 Series

Models carries over from the information provided for VX Series Models, noting the following:

• A revised pressure control solenoid was introduced with the MY2003 automatic transmissions, resulting in a

new pressure checking procedure and results.

For information relating to the hydraulic/mechanical diagnosis of the Hydra-Matic 4L60-E automatic transmission

fitted to V2 Ser ies Models not c over ed in this Sec tion, r ef er to Sectio n 7C3 – HY DRA-MATIC 4L60-E AUTOM ATIC

TRANSMISSION – HYDRAULIC/MECHANICAL DIAGNOSIS, in the VX Series Service Information.

3.1 LINE P RE SSURE CHECK

PRELIMINARY INFORMATION

Line pressures are calibrated for two sets of gear ranges – Drive/Park/Neutral and Reverse. This allows the

transmission line pressure to be appropriate for two different pressure needs in different gear ranges:

Gear Range Line Pressure Range

Drive, Park or Neutral...... 380 – 1,300 kPa

Reverse........................... 440 – 2,235 kPa

Before performing a line pressure check, verify that the pressure control (PC) solenoid is receiving the correct

electrical signal from the PCM, as follows:

1. Install Tech 2. Refer to 3.1 CONNECTING TECH 2 TO THE VEHICLE in Section 0C - TECH 2, in the VX

Series I Service Information for the necessary procedure.

2. Start the engine and firmly apply the park brake.

3. Check for stored diagnostic trouble code/s (DTC) and in particular, for a pressure control solenoid DTC.

4. Rectify as necessary.

NOTE: The transmission may experience harsh, soft or mushy shifts for up to two days after this procedure.

PROCEDURE

1. Check engine and transmission fluid levels.

2. Check the manual linkage for correct adjustment and wear.

3. If not previously carried out, install Tech 2 to the vehicle. Refer to 3.1 CONNECTING TECH 2 TO THE

VEHICLE in Section 0C - TECH 2, in the VX Series I Service Information for the necessary procedure.

4. Install an oil pressure gauge such as Tool

J21867 or commercial equivalent, into the line

pressure tapping point on the transmission, as

shown.

5. Select ‘P’ (Park) range and firmly apply the

park brake.

6. Start the engine and allow to warm up, at idle.

7. Access ‘Miscellaneous Tests’ on Tech 2, then

the PCS CONTROL test.

8. Increase ACTUAL PCS in 0.1 Amp increments

on Tech 2 and read the corresponding line

pressure reading on the fluid pressure gauge.

(Allow the pressure to stabilise for 5 seconds

after each current change.

9. Compare the pressure readings against the line

pressures provided in the following chart.

IMPORTANT: Total test running time should not

exceed 2 minutes or transmission damage could

occur.

Figure 7C-5

NOTE 1: Pressures are to be taken at an engine speed of 1,500 rpm and a temperature of 66°C. Line pressure

drops as temperature increases.

NOTE 2: If pressure readings differ greatly from the line pressure chart, refer to the Diagnostic Section in either

Section 6C1 POWERTRAIN MANAGEMENT – V6 SUPERCHARGED ENGINE or Section 6C3 POWERTRAIN

MANAGEMENT – GEN III V8 ENGINE in the VX Series Service Information.

NOTE 3: T ech 2 is only able to control the PC solenoid in Park , and Neutral, with the vehicle stopped. This protects

the clutch packs from extremely high or low pressures in Drive or Reverse ranges.

Line Pressure (kPa)

Pressure Control Solenoid

Current (Amp) V6 Engine GEN III V8

Engine

0.00 1,261 – 1,399 1,369 – 1,507

0.10 1,257 – 1,395 1,356 – 1,494

0.20 1,233 – 1,371 1,334 – 1,472

0.30 1,201 – 1,339 1,299 – 1,437

0.40 1,139 – 1,277 1,229 – 1,367

0.50 1,055 – 1,193 1,143 – 1,281

0.60 921 – 1,059 1,016 – 1,154

0.70 818 – 956 868 – 1,006

0.80 649 – 787 693 – 831

0.90 439 – 577 481 – 619

1.00 379 – 517 333 – 471

1.10 339 – 477 —

4. ON-VEHICLE SERVICING

The information regarding the on vehicle servicing of the automatic transmission as fitted to V2 Series Models

carries over from the information provided for VX Series Models, noting the following;

• W ith the introduction of the MY2003 Hydra-Matic 4L60-E automatic transm ission into V2 Series Models during

October 2002, new quick-connect fittings have replaced the flare nut fittings where the transmission cooler

pipes connect to the radiator and transmission.

For inform ation r elating to on- vehicle s ervic ing of the Hydra-Matic 4L60-E automatic trans mission f itted to V2 Series

Models not covered in this Section, ref er to Section 7C4 – HY DRA- M AT IC 4L60-E AUTOM ATIC TRANSMISSION

– ON-VEHICLE SERVICING, in the VX Series Service Information.

4.1 COOLER PIP E QUICK-CONNECT FITTING

REMOVE

1. Release the verifier disc (2) by pulling back

with the fingertips, then slide back down the

cooler pipe (1).

2. Open the cooler line release Tool J41623-B

and slip over the cooler pipe to be

disconnected from the transmission, above the

verifier disc (2), as shown.

3. Slide the release tool along the pipe to engage

with the quick-connect fitting.

4. While pushing inwards, rotate the tool about

one sixth of a turn to release the spring clip

holding the pipe.

5. With the release tool held in this position, pull

back on the cooler pipe to release.

6. Repeat this process with the remaining pipe

and quick-connect fitting.

7. Plug all openings to prevent foreign matter

entry.

Figure 7C-6

REINSTALL

1. Remove plugs from cooler pipes and quick

connect fittings, wipe the pipes clean, then

smear with clean automatic transmission fluid.

2. Push each pipe into its respective quick

connect fitting.

3. Attempt to pull the pipe free to ensure correct

engagement.

4. Slide each verifier dis c up to the quick c onnect

fitting. If it engages with the fitting, then the

pipe has been correctly installed.

Techline

5. UNIT REPAIR

The information regarding the hydraulic/mechanical diagnosis of the automatic transmission as fitted to V2 Series

Models carries over from the information provided for VX Series Models, noting the following:

• Eff ect ive f rom a Julian build date of ‘1HX D002 A 0000001’, the Torque Converter Clutc h (TCC) Regulator Valve

exhaust port was r educed in size. This change has m eant that, not only has the control valve body changed but

the spac er plate and both gask ets have also been m odified. T he early and later gaskets and s pacer plates c an

be physically identified as shown in Figure 7C-1.

• W ith the introduction of the MY2003 Hydra-Matic 4L60-E automatic transm ission into V2 Series Models during

October 2002, the pressure control solenoid and boost valve bushing was revised. As the design of the wiring

harness connector for the pressure control solenoid is also new, the internal transmission wiring harness also

changes.

• For the HAD transmission f itted to V2 Series Models with the GEN III V8 engine, the num ber of plates in the 3-4

clutch pack has been increased from six to seven plates. To achieve this result without undergoing major

internal com ponent changes, the plates are thinner. T his means that the same selective plates can be used to

achieve the same end float specification.

For inf ormation relating to unit repair of the Hydra- Matic 4L60-E automatic transmiss ion fitted to V2 Series Models,

refer to Section 7C5 – HYDRA-MATIC 4L60-E AUTOMATIC TRANSMISSION – UNIT REPAIR, in the VX Series

Service Information.

6. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASSIFICATION

J41623-B

COOLER PIPE QUICK-CONNECT

RELEASE TOOL

New release.

Mandatory