NEW PRODUCT ANNOUNCEMENT HYDRA-MATIC 4L60-E

SUBJECT: NEW PRODUCT ANNOUNCEMENT HYDRA-MATIC 4L60-E

VEHICLES AFFECTED: ALL 1993 C/K - TRUCKS UNDER 8600 GVW S/T - TRUCKS WITH 4.3L NON TURBO M/L AND G - VANS

BULLETIN COVERS:

This bulletin covers the HYDRA-MATIC 4L60-E Service Replacement Transmission Assembly (SRTA) Program and limited on-car repair guidelines. SRTA models and service parts can be ordered from your local General Motors Service Parts Operations (GMSPO) Parts Distribution Centre.

The HYDRA-MATIC 4L60-E is a new transmission model that has electronic shift controls to control shift points.

SRTA ADVANTAGES:

A SRTA is the product of a highly successful, customer satisfaction driven program that parallels the existing HYDRA-MATIC 3T40, HYDRA-MATIC 4T60 and HYDRA-MATIC 4L60 programs.

GENERAL GUIDELINES:

On-Car Service or SRTA:

-All service parts will be available at a later date so that bench repairs can be performed. Until then, limited on-car repairs or SRTA will be the only service options available.

-Transmission conditions considered for SRTA usage:

-All repairs that cannot be corrected by replacement of the parts are shown in (Figure 1).

-Dealer HYDRA-MATIC 4L60-E transmission repairs include:

-Limited on-vehicle serviceable items. Reference Figure 1.

-Parts needed to perform limited on-vehicle service on a HYDRA-MATIC 4L60-E transmission are available through your local Parts Distribution Centre (PDC).

IMPORTANT: Do not attempt repairs on a HYDRA-MATIC 4L60-E, unless the part is shown in (Figure 1) and listed in the repair parts list in this bulletin. All returned HYDRA-MATIC 4L60-E transmissions will be disassembled and inspected in an effort to increase product integrity. Attempting repairs could destroy root cause analysis data.

COOLER FLUSHING:

Cooler flushing and a flow check MUST be performed whenever a transmission is removed for service. It is essential to flush the cooler after SRTA installation, major overhaul, in the case of pump or torque converter replacement, or when fluid contamination is suspected. Use Kent-Moore tool J35944 and solvent J35944-20 to flush the cooler. Instructions are published in each service manual On-vehicle Service Section.

SERVICE PARTS INFORMATION:

HYDRA-MATIC 4L60-E SRTA MODEL REPLACEMENT CHART

SRTA PART # MODEL DESCRIPTION ----------- ----- ----------- 8685955 3CBD 4.3L LB4 C TRUCK & G VAN

8685956 3CFD 5.0L L03 C TRUCK

8685957 3CJD 5.7L L05 C TRUCK

8685958 3CLD 6.2L DIESEL C TRUCK & G VAN

8685959 3KAD 4.3L LB4 K TRUCK

8685960 3KBD 5.0L L03 K TRUCK

8685961 3KCD 5.7L L05 K TRUCK

8685962 3KDD 6.2L DIESEL K TRUCK

8685963 3MJD 4.3L LB4 M VAN

8685964 3MDD 4.3L L35 L VAN

8685965 3MND 4.3L LB4 L VAN

8685966 3MSD 4.3L L35 M VAN

6865967 3SHD 4.3L LB4 S TRUCK

8685968 3TAD 4.3L L35 T TRUCK

8685969 3TBD 4.3L L35 S TRUCK

8685970 3TLD 4.3L LB4 T TRUCK

1993 HYDRA-MATIC 4L60-E SERVICEABLE COMPONENTS

PART NUMBER ILL. NO. DESCRIPTION ----------- -------- ----------- 8677662 10 CONNECTOR, OIL COOLER PIPE

8628864 11 PLUG, CASE SERVO

8642273 12 SPRING, SERVO RETURN

8680499 13 PIN, 2ND APPLY PISTON

8680500 refer model number

8680501 refer model number

8642105 14 RING, RETAINER (2ND APPLY PISTON)

8642416 15 RETAINER, SERVO CUSHION SPRING

8642539 16 SPRING, SERVO CUSHION

8642613 17 PISTON, 2ND APPLY

8642924 18 RING, OIL SEAL (2ND APPLY PISTON-OUTER)

8642925 19 RING, OIL SEAL (2ND APPLY PISTON-INNER)

8673039 20 HOUSING, SERVO PISTON (INNER)

8673041 refer model number

8642112 21 SEAL, O-RING

8642106 22 SPRING, SERVO APPLY PIN

8642107 23 WASHER, SERVO APPLY PIN

9415640 24 RING, RETAINER (APPLY PIN)

8642478 25 PISTON, 4TH APPLY

8642480 26 RING, OIL SEAL (4TH APPLY PISTON-OUTER)

8647351 27 SEAL, O-RING (2-4 SERVO COVER)

8642979 28 COVER, 2-4 SERVO

8642124 29 RING, SERVO COVER RETAINING

1358899 30 SEAL, CASE EXTENSION TO CASE

8667634 31 EXTENSION, CASE

8667636 refer model number

11503428 32 BOLT, CASE EXTENSION TO CASE

6260048 33 BUSHING, CASE EXTENSION

8673526 34 SEAL ASSEMBLY, CASE EXTENSION OIL

8655314 35 BOLT, SPEED SENSOR RETAINING

8673299 36 SPEED SENSOR, INTERNAL TRANSMISSION

8685950 71 SEAL, FILTER

8685950 72 FILTER ASSEMBLY, TRANSMISSION OIL

8685950 73 GASKET, TRANSMISSION OIL PAN

8654701 74 MAGNET, CHIP COLLECTOR

8663948 75 PAN, TRANSMISSION OIL

15614709 76 SCREW, TRANSMISSION OIL PAN

Part numbers are accurate at the time of printing and are subject to change. Refer to the latest GMSPO Parts Catalogue for part numbers of SRTA models and service parts.

HYDRA-MATIC 4L60-E QUICK CHECK PROCEDURE:

1. Write down customer complaint.

2. Check fluid level and condition:

-Burned? Remember brown colour of the fluid may be OK. Refer to Service Manual.

-Low or overfilled? Correct as necessary.

3. Use the TECH 1 to check for stored Diagnostic Trouble Codes (DTC).

-Remember, code 12 tells you that the diagnostic function of PCM is functioning correctly.

-If there is a stored transmission code other than code 12, refer to Section 7A-14C of the 1993

-Service Manual for diagnostic procedures.

4. Clear codes, test drive car. Monitor powertrain with a TECH 1. For shift points refer to the shift speed chart, (Figure 2). Remember when the gear selector is in D2 this will cause a 2nd gear start.

5. Recheck for stored codes. Correct all codes before continuing.

6. If transmission operates properly--stop.

7. For a harsh or soft shift condition confirm correct calibration prom, then perform transmission line pressure check procedure, (Figure 3). If line pressure is too high or too low, replace the transmission.

8. For a poor performance condition verify engine performance, then refer to torque converter evaluation in Section 7A-14A of the 1993 Service Manual.

9. For a vibration or noise condition refer to torque converter vibration test procedure in Section 7A-14A of the 1993 Service Manual.

10. If all the steps check out okay and the transmission still does not function correctly, refer to Section 7A-14A of the 1993 Service Manual for diagnosis information. If the diagnosis information determines that an internal component of the transmission needs to be serviced, then replace the transmission. Do not disassemble the transmission. See Page 2 for replacement service part numbers.

HYDRA-MATIC 4L60-E TRANSMISSION IDENTIFICATION INFORMATION:

Transmission identification information (Figure 4) and the SRTA model replacement chart will assist in selecting the correct SRTA unit to order from your local Parts Distribution Centre.

SRTA PROCESSING PROCEDURE:

Each SRTA unit will be in a container which must be used for core return of the original HYDRA-MATIC 4L60-E assembly. A SRTA Information Packet is included with each SRTA unit. The contents of this envelope are to be removed and used as described with each illustration on the following pages.

SRTA PROCESSING PROCEDURES-INFORMATION PACKET:

The contents of this envelope include Limited Warranty Information, Dealer Product Feedback Form, Core Exchange Return Procedure, and a pre-addressed return mailing envelope.

SRTA PROCESSING PROCEDURES-CORE EXCHANGE RETURN:

The core return procedure provides detailed instructions for the GM dealer on handling the SRTA and original HYDRA-MATIC 4L60-E units.

SRTA PROCESSING PROCEDURE-FAILURE ANALYSIS INFORMATION:

This Product Feedback Form is to be completed by the service manager and/or technician. Fill out these forms as completely as possible to provide information which can be used for analysis. This valuable input can result in future product refinement through corrective action. Insert the white copy of the completed form and a copy of the repair order into the SRTA Information Packet envelope, reseal the envelope and wire tag it to the bell housing of the unit being returned for core exchange.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.