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R&I – TH440-TH440E Diagnosis

General Motors TH440/TH440E (4T60/4T60E)
Rear Wheel Drive Overdrive Transmission

 

TH440/TH440E (4T60/4T60E) Diagnosis

  1. Scan for codes & write down.
    • All driveability codes must be addressed before transmission diagnosis.
    • If the computer system does not go into closed loop the lock-up torque converter will not engage.
  2. Clear codes.  Start vehicle – check fluid level (always read BOTH sides of dipstick & use the lowest reading) & condition (color & odor).  We recommend this transmission be 1 quart over full (approximately 1 to 1-1/4 inches above the full mark).
  3. Road test noting shift points & lock-up – do this under light, medium and heavy throttle.
    • Lock-up test – Use Overdrive range  “Circled D”
    • Allow transmission to shift to highest gear.
    • Hold steady speed and note tach.
    • Hold steady speed, depress brake pedal with left foot just enough to open T.C.C. circuit and read tach – Should be 200-300 rpm gain.
  4. Test kickdown operation from 4-3 and 4-3-2.
  5. Test engine braking in all forward gears.
  6. Re-scan to see which codes may have returned.
  7. Hoist vehicle – Remove pan & filter – Open filter at the seam and open filter media to check for debris.
  8. The 4T60 has only a lockup solenoid and and ECM controlled switches for electronic equipment.  Pressure is controlled by the modulator.  Shift points are controlled by the TV cable.  These can be adjusted independent of each other.
  9. The 4T60E pressure is controlled by the vacuum modulator.  Shifting is controlled by the computer. There are two shift solenoids and one or two lockup solenoids.
  10. If codes refer to solenoids or circuit problems, pinout checks should be performed on these components individually before condemning transmission.
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TH440/TH440E (4T60/4T60E) Installation/Removal

  1. Disconnect TV cable from throttle (440 only).
  2. Disconnect transmission electrical connector.
  3. Remove Intake air bellows and cruise control servo if necessary.
  4. Remove manual lever and manual lever position sensor.
  5. Remove top 3 or 4 bellhousing bolts (depending upon application).
  6. Install engine support fixture.
  7. Hoist vehicle – check for leaks.  Remove wheels to determine if vehicle has a full frame or half frame that must be removed

Full Frame Vehicles

  1. Remove both balljoints from spindles.
  2. Remove all nuts and bolts from engine and transmission mounts.
  3. Unbolt steering rack from subframe and support rack to prevent slip joint from disengaging.
  4. Remove any bolts holding straps for a/c hoses, wiring looms or powersteering lines.
  5. Support frame.  Remove bolts holding frame to body.  Remove frame.
  6. Support transaxle with transmission jack and secure transaxle to jack.
  7. Remove axles from transaxle.
  8. Remove speed sensor wires.
  9. Remove torque converter cover and torque converter bolts.
  10. Remove cooler lines.
  11. Remove bolts from right side transmission support and remaining 2 bellhousing bolts.
  12. Slide transmission away from engine and lower.
  13. FLUSH COOLER with a clean, filtered solvent for 20 minutes in both directions.
  14. Install add-on filter in the return (upper) cooler line.  Be sure to connect the red connector on tranny to the red connector on filter.  The other filter connector will connect to the cooler at the radiator. NOTE:  The filter cartridge we use is a bi-directional filter.  Most replacement filters are “one way” filters.  If the filter is incorrectly installed, when you replace the filter cartridge in the future, you will experience catastrophic transmission failure due to lack of fluid flow as soon as the filter is replaced and the vehicle is driven!
  15. TO INSTALL TRANNY reverse steps 11 thru 4.  In step #10 use blue Loctite on bellhousing bolts & tighten very tight by hand.  In step #4 use red Loctite on torque converter bolts and torque to specifications.
  16. Lower vehicle – ADJUST TV CABLE (440 only). Leave the TV cable attached to the carburetor while adjusting !!  In the pictures below the TV cable has been removed for clarity only!
    • See pictures for steps
    • FAILURE TO RESET TV CABLE WILL RESULT IN IMMEDIATE CLUTCH AND BAND FAILURE AND NO WARRANTY.
  17. Pour in 4 quarts transmission fluid  – start vehicle – finish filling tranny.
  18. Check fluid level (always read BOTH sides of dipstick & use the lowest reading) & check for leaks.
  19. Road test – under normal driving conditions shift points should be:
    • At light throttle:
      • 1-2:  12-15 mph
      • 2-3:  22-25 mph
      • 3-4:  47-50 mph
    • At medium throttle:
      • 1-2:  20-25 mph
      • 2-3:  35-40 mph
      • 3-4:  50-55 mph
    • Shift points will be higher as throttle increases.
    • You should avoid 3/4 to full throttle application until the transmission shift points have been checked at light and medium throttle and check out OK.
    • Shifts should be crisp, not drawn out or with flare.
    • Lock-up should apply in 3rd & 4th gears – see diagnosis section above for lock-up test.
  20. If the old tranny is suspected of being overheated (fluid very stinky) the initial road test should be no more than a mile or two long , just long enough to bring the tranny up to operating temperature. A cooler flow test should be performed immediately after the road test (when the tranny is at operating temperature) by removing the cooler return line (top line) at the transmission.  Put the line in an uncontaminated plastic jug and start engine.  Run engine for 30 seconds and shut engine off.  Check amount of oil in the jug.  Normal flow @ idle should be 2 quarts in 30 seconds.  If flow is normal reconnect tranny line, add back fluid and recheck for leaks.  If flow is restricted the cooler must be replaced.  A complete road test may now be performed once normal cooler flow is determined.

Half Frame Vehicles

  1. Remove left balljoint from spindle.
  2. Remove any bolts holding straps for a/c hoses, wiring looms or powersteering lines.
  3. Remove nuts and bolts from mounts attached to frame.
  4. Remove nuts and bolts securing left frame section and remove.
  5. Remove flywheel dust cover and torque converter bolts.
  6. Support transaxle with transmission jack and secure to jack.
  7. Remove cooler lines.
  8. Disconnect speedometer or wires.
  9. Remove both axles – may be left in wheel hubs.
  10. Remove bolts from right side of transmission to engine bracket and the remaining bellhousing bolts.
  11. Slide transmission away from engine and slowly lower, disengaging right axle while lowering.
  12. Install add-on filter in the return (upper) cooler line.  Be sure to connect the red connector on tranny to the red connector on filter.  The other filter connector will connect to the cooler at the radiator.
    NOTE:
      The filter cartridge we use is a bi-directional filter.  Most replacement filters are “one way” filters.  If the filter is incorrectly installed, when you replace the filter cartridge in the future, you will experience catastrophic transmission failure due to lack of fluid flow as soon as the filter is replaced and the vehicle is driven!
  13. TO INSTALL TRANNY reverse steps 11 thru 4.  In step #10 use blue Loctite on bellhousing bolts & tighten very tight by hand.  In step #4 use red Loctite on torque converter bolts and torque to specifications.
  14. Pour in 4 quarts transmission fluid  – start vehicle – finish filling tranny.
  15. Check fluid level (always read BOTH sides of dipstick & use the lowest reading) & check for leaks.
  16. Road test – under normal driving conditions shift points should be:
    • At light throttle:
      • 1-2:  12-15 mph
      • 2-3:  22-25 mph
      • 3-4:  47-50 mph
    • At medium throttle:
      • 1-2:  20-25 mph
      • 2-3:  35-40 mph
      • 3-4:  50-55 mph
    • Shift points will be higher as throttle increases.
    • You should avoid 3/4 to full throttle application until the transmission shift points have been checked at light and medium throttle and check out OK.
    • Shifts should be crisp, not drawn out or with flare.
    • Lock-up should apply in 3rd & 4th gears – see diagnosis section above for lock-up test.
    • If the old tranny is suspected of being overheated (fluid very stinky) the initial road test should be no more than a mile or two long , just long enough to bring the tranny up to operating temperature. A cooler flow test should be performed immediately after the road test (when the tranny is at operating temperature) by removing the cooler return line (top line) at the transmission.  Put the line in an uncontaminated plastic jug and start engine.  Run engine for 30 seconds and shut engine off.  Check amount of oil in the jug.  Normal flow @ idle should be 2 quarts in 30 seconds.  If flow is normal reconnect tranny line, add back fluid and recheck for leaks.  If flow is restricted the cooler must be replaced.  A complete road test may now be performed once normal cooler flow is determined.