PLEASE READ THIS BEFORE BEGINNING THE INSTALLATION
When using the 57757BHP kit, the Red Eagle®
friction plates and the Kolene® type steel plates furnish a much shorter and firmer
2-3 shift. Vehicles that will benefit from the 57757BHP kit include
Hi-Performance, street rods, and race applications. Of course, all of the durability and
performance benefits listed below are also achieved. VERY IMPORTANT: The 57757BHP
kit performs very well in a true hi-performance application but should not be used
in regular or heavy duty applications. Since the 2-3 shift will be significantly
shorter and firmer with the 57757BHP kit, you may receive customer
complaints with regular and heavy duty vehicles. To get the full benefit of these kits,
please be sure to select the right kit. Thank you.
DURABILITY AND PERFORMANCE BENEFITS OF THESE KITS ARE:
The extra capacity clutch setup in these kits offers a
significant increase in overall durability and performance to avoid premature friction
element distress or burnup. This is accomplished by spreading the apply and energy loads
over more friction plate surface area. The additional plates greatly increase the overall
clutch pack resiliency which can be best described as having an increase in clutch pack
accumulation. Therefore, the apply and release of the 3-4 clutch will be much smoother.
The clutch kits offer you the ability to confidently repair 4L60’s and 4L60-E’s
in regular vehicle applications as well as the heavy duty vehicles such as on/off road
trucks, commercial vehicles, and sporty hi-performance vehicles. For hi-performance,
street rods, or race car applications... the 57757BHP is the "last
word".
Begin installation by identifying the input housing components you will
be working with. These components are listed below in items "A" through
"E". The technical terms used to identify each component are commonly used in
most OEM and aftermarket service manuals.
A. 3-4 clutch apply ring: The total height of the
apply ring determines the total number of friction plates that can be installed for a V-6
or V-8 application. Stand the apply ring on a work table with the tall legs facing up.
Measure from the work table to the top of the legs. V-6’s will measure 3.975"
while V-8’s will measure 3.800".
B. 3-4 clutch retainer ring:
Has 5 short legs to mate
against item "A" and is .055" thick.
C. 3-4 apply plate:
Can be flat on both sides, can be
stepped on one side only, or can be stepped on both sides for some 1990-up models.
D. 3-4 clutch backing plate:
The factory used a
variety of different thicknesses identified by a number stamped on top. Number 3
(.198") and number 7 (.190") are the most commonly found in the units we
checked. You will be reinstalling these backing plates on some stackups.
E. Top backing plate snap ring:
Early models are
.128" thick, late models are .093" thick. The thickness of the snap ring is
matched to the specific housing snap ring groove. There is a custom snap ring furnished in
this kit that measures .062" thick. This snap ring will be used in situations where
the total clutch pack clearance is too tight.
INSTALLATION OF THE POWERPACK® KITS
TECHNICAL NOTE:
Dimensional differences can exist in the
various input housings and housing components. The recommended clutch pack stackups must
be exact in each and every installation. In addition, the original stepped apply plates
(item "C") require a steel plate against it which takes up needless space in the
clutch pack. We recommend installing the furnished .125" flat backing plate in place
of the stepped apply plate. First, assemble the clutch pack according to the application
you have. Air-check the 3-4 clutch several times to seat all the components. If the clutch
clearance is not .025" - 040", use our suggestions listed under
Adjusting The Clutch Pack Clearance.
Early V-6 regular or heavy duty applications:
Reinstall the original .125" apply plate. Install SEVEN frictions, SIX steels, and
the furnished .125" backing plate. Reinstall the original .128" top snap ring.
Late V-6 regular or heavy duty applications with stepped apply
plate: Discard the original stepped apply plate. Install the furnished .125"
backing plate, SEVEN frictions, and SIX steels. Reinstall the #3 and #7 top backing plates
and the original .093" top snap ring.
Early V-8 regular or heavy duty applications (option 1):
Reinstall the original .125" apply plate. Install EIGHT frictions and SEVEN steels
along with the #3 or #7 top backing plate. Reinstall the original .128" top snap
ring.
Early V-8 regular or heavy duty applications (option 2): Reinstall
the original .125" apply plate. Install EIGHT frictions, SEVEN steels, and the
.125" top backing plate furnished. Install the custom .062" snap ring.
Late V-8 regular or heavy duty applications with original
stepped apply plate: Reinstall the original stepped apply plate. Install EIGHT
frictions and EIGHT steel plates. Reinstall the original #3 or #7 top backing plates and
the original .093" snap ring.
IMPORTANT: FIRST install a steel plate on top
of the stepped apply plate.
Early V-8 performance or race applications: Reinstall
the original .125" apply plate. Install NINE frictions, EIGHT steels, and the
.125" top backing plate furnished. Install the original .128" top snap ring or
the furnished .062" custom snap ring.
Late V-8 performance or race applications with stepped apply
plate: Install NINE frictions and EIGHT steels. Reinstall the original #3 or #7
top backing plate and the original .093" top snap ring or the furnished .062"
snap ring.
IMPORTANT: Be sure to presoak the friction plates in
ATF for fifteen minutes or more. This will dissipate heat on initial start-up and apply to
avoid friction paper glazing!
INSTALLATION FOR ALL 4L60-E ELECTRONIC UNITS
You may encounter specific element design differences
regarding the 3-4 clutch retainer ring (item "B") and the 3-4 apply plate (item
"C"). On some units, items "B" and "C" are a singular
component. It can be easily identified as being a thick apply plate, flat on both sides
with five extended lugs that are placed onto the legs of the 3-4 clutch apply ring (item
"A") and it also measures .225" in thickness. If your unit has this design,
we recommend the following stackup: If item "A" should measure 3.800", you
will be installing a NINE friction plate setup. Reinstall the singular
design apply plate and ensure that it is fully seated down onto the legs of item
"A". Install one of the friction plates directly on top of the apply
plate. Install the remaining friction and steel plates in the conventional manner. Install
the .125" backing plate furnished along with the original .093" top snap ring.
SETTING AND ADJUSTING THE 3-4 CLUTCH PACK CLEARANCE
After completing the assembly of the 3-4 clutch pack, air
check it several times to seat all the installed components. Insert a feeler gauge between
the top friction plate and the bottom of the top backing plate. For the best overall
performance of 2-3 and 3-2 shifts, we recommend setting the 3-4 clutch pack clearance to
.025" - .040". If there is too much clearance, remove
one or two of the .060" steels and install one or two of the standard .076"
steels furnished. For clearances that are too tight on any applications where the stepped
apply plate has been discarded, use another .125" flat apply plate (not
furnished) at the top of the pack in place of the original #3 or #7 backing plate.
To achieve the recommended clutch clearance, you can intermix and/or exchange the top
backing plates, steel plates, and/or top snap rings.
