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Performance &Heavy Duty
Transmission Parts
PERFORMANCE
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Sonnax ProductsFind information on thousands of
Sonnax parts quickly and easily
online. We offer a full range of
transmission, high performance
and torque converter products, plus
specialized drivetrain components.
Request a catalog if you want a
handy reference for the bench.
Technical ResourcesComprehensive instructions for
Sonnax parts are available on
our website any time you need
them. The popular Sonnax online
technical library also is a great
resource, with hundreds of articles
on everyday transmission issues
as well as unique rebuilding
challenges.
Where to BuyReady to order? Find out whereto purchase genuine Sonnax parts
from an online listing of authorized
Sonnax distributors in the U.S.
and other countries.
Contact Sonnax
(800) 843-2600 (802) 463-9722
www.sonnax.com
Sonnax.com
The #1 Site for Cutting-Edge
Transmission Solutions
Become a Sonnax Insider!Get the scoop on all the newest
Sonnax products & tech resources:
SmartShellHD Reaction Shell Kit ........ 2
4L60-E Performance Pack .......................3
Line Pressure Booster Kits ..................... 4
Input Housing Shafts & Kits .............56
Pinless Accumulator Piston Kits .............5
2nd& 4thGear Servos ...............................7
Billet Forward Piston .............................. 8
Heavy-Duty 2-3 Shift Valve .................... 8
Bushing Upgrades .................................. 8
Parts Listing .................................... 910
Sonnax Build Charts ................................11
Contents
Heavy Duty &
Performance
Transmission Parts
PERFORMANCE
1 Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1 2013 Sonnax Industries, Inc.
Get your
gearhead on
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SmartShell
Heavy-Duty Reaction Shell Kit
SmartShell Videoat www.sonnax.comGo inside the 4L60 sun gear shell to see the
source of common failures and learn how the
SmartShell stops them all.
Scan code with smartphone to watch video now!
SmartShell Video Also On
2www.sonnax.comGet your gearhead on
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4L60-EPerformance
PackThe best working performance
units we have done,
and thats not from me,
but my customers.
B. Bastedo
Advanced Transmission Care
Mooresville, N.C.
Pump Parts
Pressure Regulator Spring
Boost Valve, .490"
Pump Slide Spring
Accumulator Parts
1-2 Pinless Piston Kit
1-2 Piston Springs
1-2 Waved Spring
Valve Body Parts
Forward Pinless
Accumulator Piston Kit Accumulator Valve Shim
TCC Spring & Valve
Servo Parts
4thServo Return Spring
Servo Cushion Spring
Servo Piston
D-Ring Kit
Case Parts
3-4 Accumulator Piston Kit
3-4 Accumulator Spring
Servo Release
Check Valve
3 Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1 2013 Sonnax Industries, Inc.
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The SMART, affordable
& safe wayto raise line pressure.Sonnaxs unique combination of larger boost valves and stronger
springs results in normal engagements, normal light throttle shifts
and smooth coast-down shifts.
When pushed harder or driven aggressively, pressure increase
becomes progressively greater, ensuring that shifts are not too soft.
Line Pressure
Booster Kits
The Sonnax progressive
boost valve will put a smile
on your customers face.
D. Stewart
Dan's Service Center
Cliff, N.M.
4www.sonnax.comGet your gearhead on
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Input Drum
Reinforcement Kit Chrome-moly steel sleeve
Reworked OE piston & O-ring
Sleeve design will not block
clutch feed oil
Pinless Accumulator
Piston Kits
Pinless design eliminates the
possibility of pin leakage; steel
balls plug existing pin bore
Dual seals stabilize & provide
a tight seal even after thousands
of cycles
Added length stabilizes piston
to prevent piston cocking
Replacement seals also available
77998-03K
77987-01K
The perfect upgrades
for OE-strength input shafts.
High strength material for high-horsepower
street or strip applications
Chamfered feed holes and shot peening reduce
stress cracks and increase service life
Deep cryogenic treatment for extra toughness
Each accumulator kit includes:
Pinless Accumulator Piston
D-Ring & PTFE Seal
Steel Balls (2)
77733-10S
77733-12S
77733-11S
300mm & 298mm
Heavy Duty Input Shafts
5 Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1 2013 Sonnax Industries, Inc.
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Although incremental improvements to aftermarket parts have
been made addressing 4L60-series 3-4 clutch problems, they
failed to keep pace with steadily increasing power levels of
modern performance engines...until now!
The Sonnax Smart-Tech tackles ALL the 3-4 clutch
issues of the 4L60 as no other housing has done before!
The Smart-Tech requires 91-later 3-4
apply ring, 97-later ring gear and
96-earlier aluminum forward piston o
Sonnax billet forward piston 77764-0
(see pg. 8). It cannotbe used with
stamped steel forward piston.
Limited 3-4 Clutch Capacity
Anchor (backing) plate works with redesigned apply
plate for more room and clutch options for eight or
nine frictions for increased torque capacity.
Smart-Tech
Input Housing Kit
3-4 Backing Plate Flexing & DistortionZero-flex, bolt-on anchor plate replaces
OE backing plate to eliminate clutch pack
distortion and uneven clamping pressure.
Input Housing Fatigue FailureTreated housing is significantly
more resistant to fatigue failure.
Aluminum Housing BreakageSteel input drum reinforcement sleeve
prevents breakage in the shaft/spline area.
3-4 Retaining Ring Blow-OutFifteen bolts secure anchor plate,
eliminating snap-ring and blow-out concerns.
Smart-Tech kits
also come assemb
with input shaft
The ULTIMATE
3-4 Clutch Pack
SOLUTION
6www.sonnax.comGet your gearhead on
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18% More apply area than the
Corvette servo (largest OE).
Maximizes holding power
in 2ndgear with more
positive 1-2 and 2-3 shifts.
Dual seals ensure positive
band apply/release and
eliminate cross leaks.
Apply pin has added seals to
reduce leakage of 3rdgear pressure.
2ndGear Super Hold Servo KitThe perfect upgradefor more
holding power without excessively harshupshifts and downshifts.
4thGear Super Hold
Dual Servo Kit 40% More apply area.
Patented dual-piston design.
D-ring seals for improved sealing.
Super HoldServos
More Apply Area
Easy to InstallNo transmission removal is required.
Billet AluminumFor super strength and durability.
7 Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1 2013 Sonnax Industries, Inc.
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Heavy-Duty 2-3 Shift Valve Drop-In replacement
Extends life of the forward clutch & input sprag
This Sonnax valve applies the overrun clutch inD3, 1st, 2nd and 3rd gears for added durability,
where the OE valve applies the overrun clutch only
in D3, 3rd gear. This valve also works well with
aftermarket electronic paddle shifters to allow full downshift
engine braking in 2nd while the shifter remains in the D3 position.
eliminates breakage
caused by rough housings & high stress.
This piston can be used by itself or with a variety of Sonnax input drum and housing reinforcement kits.
See pages 5 and 6 for details.
Customize transmission
performance with key part
for more speed, strength
and durability!Billet
Forward
Piston
Rear Stator Support BushingThe BESToptionto
support the 20 lb. inputhousing & improve reliability.
Better-fitting, drop-in upgrade
PTFE-coated
Wide Sun Gear BushingStopsoil Leakage
1.5X Wider than OE bushing
to maximize support for
sun gear & reaction shell
Steel-backed bronze
Pump Bushing Drop-in replacement
PTFE-coated
Bushin
g
Upgrades
8www.sonnax.comGet your gearhead on
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Build the Transmission
Sonnax specializes in a wide range of innovative, high-quality
parts for the very best everyday or performance rebuilds.
Items listed in RED here should always be considered
for performance or heavy-duty applications.
9 Sonnax 4L60/E Performance & Heavy Duty Transmission Catalog Vol. 1 2013 Sonnax Industries, Inc.
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Visitwww.sonnax.com for the most
current product offerings, tech support,
distributor listings & more!
10www.sonnax.comGet your gearhead on
Scan code with smartphone to browse all Sonnax 4L60-E parts online.
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PERFORMANCE
Use these charts to get the most
out of your Sonnax 4L60-series rebuild!
Performance Build
Option A Option B
Line Pressure Booster Kit See page 4 Performance Pack HP-4L60E-01
SmartShell 77749-02K SmartShell 77749-02K
Rear Stator Support Bushing 77002BT-01 Rear Stator Support Bushing 77002BT-01
4thGear Super Hold Servo 77767K
Choose 2nd
Gear Servo
Super Hold 77911-03K
Corvette Ratio 77701-04K
Pickup Build
Option A Option B
Line Pressure Booster Kit See page 4 Performance Pack HP-4L60E-01
SmartShell 77749-02K SmartShell 77749-02K
Rear Stator Support Bushing 77002BT-01 Rear Stator Support Bushing 77002BT-01
4thGear Super Hold Servo 77767K 4thGear Super Hold Servo 77767K
Heavy Duty 2-3 Shift Valve 77754-41 Heavy Duty 2-3 Shift Valve 77754-41
Performance Build
Performance Pack HP-4L60E-01
SmartShell 77749-02K
Rear Stator Support Bushing 77002BT-01
Heavy Duty 2-3 Shift Valve 77754-41
4thGear Super Hold Servo 77767K
2ndGear Corvette Ratio Servo 77701-04K
Input Drum Reinforcement Kit 77733-01K
Billet Forward Piston 77764-01
Choose
Wide Band
Red Band 77700-01
KevlarBand 77700-01K
*Includes rear stator support bushing.
Performance Build
Performance Pack HP-4L60E-01
SmartShell 77749-02K
Rear Stator Support Bushing 77002BT-01
Heavy Duty 2-3 Shift Valve 77754-41
4thGear Super Hold Servo 77767K
2nd Gear Super Hold Servo 77911-03K
Smart-TechInput Housing See page 6
Billet Forward Piston 77764-01
Choose
Wide Band
Red Band 77700-01
KevlarBand 77700-01K
Dont risk throwing products from different manufacturers into the same tranny
when theres no guarantee theyre all going to play nice.Installing Sonnax parts
designed to work together is the BEST and SAFEST way to upgrade a transmission.
See pages 9 & 10for more 4L60/E series
Sonnax parts IDEAL for everyday rebuilds
or performance/heavy duty applications!
Performance &Heavy Duty
Transmission Parts
Level 3
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