And last but not least, I've collected my parcel today:


I have it packed back to the box and left on the shelf till I am done with pump. The housing has an increased 3-4 clutch capacity, and can store an additional ring+friction. I wish to go with high energy carbon frictions (like Borg & Warner), but they either come in a standard set (no additional one) or 100pcs boxes. That's another piece to solve.

 

I am browsing the spares listed above and what I found, that the front bushing type that will match the actual dimension is:

Stator Support Bushing 35007A

• Bushing Style: Precision
• Material: Steel-backed copper alloy
• Width: 0.500"
• Housing Bore: 1.121"
• Inner Dia.: 1.004"
• Shaft Dia.: 1.002"

Unluckily RockAuto doesn't offer that one. There is a chance to get it at Summit Racing, but they charge $40 for shipping...
Sonnax 77005T is listed as "Bushing" without any details on dimensions, neither it is available on RA. They have some Transmaxx parts, but I am not sure of their quality. Tough nut to crack.

 

Mike, how hard would it be for me to ship parts to you? I definitely have all pieces you would need.
Brad

 

Here are the codes for pump assembly. I am still missing the front stator bushing and the filter neck:
Rear stator bushing 77002BT-01 Sonnax
Front stator bushing ????? Sonnax (this one seem ok, but none of my suppliers have it: Stator Support Bushing 35007A Bushing Style: Precision Material: Steel-backed copper alloy Width: 0.500" Housing Bore: 1.121" Inner Dia.: 1.004" Shaft Dia.: 1.002")
TCC apply valve kit 77805E-K Sonnax (no reamer needed)
Oversized pressure regulator valve 77917-07 Sonnax (need reamer 77917-TLC, can be tested)
Pump slide spring 77722-01K Sonnax
Pump stator tube teflon sealing rings 8667035 Delco
Front sealing 17458 SKF (or 17459 incl. spring clip) (Width (in) 0.365 Shaft (in) 1.747 Bore (in) 2.623 Outer Diameter (in) 2.627 Boretite Y)
O-ring (outer pump body) 24210605 Delco
Fluid screeen 8642912 Delco
Filter neck ?????????
Pump body – transmission body gasket 12337931 Delco
Fluid pump slide seal 8634906 Delco

Sonnax provides a nice manual for an oversized pressure regulator valve, showing the testing procedure (18mmHg at the test port) I am going to prepare the vacuum plate to test the pressure regulated valve at the one I have in the body pump. I hope I'll find it good, otherwise I'd have to continue with a following option:
- oversized valve which needs a reamer
- remanufactured pump (probably no performance bushings and upgrades)
- a new body pump
None of them sound good.

 

PM sent.

 

This company is in Warsaw and appears to carry GM parts. Am I missing something?

 

You truly suprised me Brad!
I gave them a call right away asking if they could machine the pump and valve body for oversized valves, and guy on the other end said "we do not do 4L60E"...
Bushing kit AT 4L60 4L60E 4L65E 4L70E 84-up - OUT OF STOCK
Transfer case gasket 4L60 4L60E 4L65E 82-11 3975707 - OUT OF STOCK

That reminds me of the anecdote on the difference in between capitalism and communism: "At a first glance, the difference was hard to note. As, for example, the kids in capitalism country have the ball to play a football. So does the kids in the communism. The difference was the ball in the capitalism country was the one that actually bounced". So - You have the suppliers and so does we. Except, the shop has small to offer for 4L60E, and amongst the list pretty much is out of stock. That what they have, they seem to be dispatching from Ukraine.

I have mentioned You in PM on the very few specialists that could comprehensively repair the US A/T. I haven't mentioned that vast part of the suppliers have the products cheapest of the cheapest, made in China. That's why I am so happy to order Delco for a decent price in RA.

UPDATE:
I've spend this morning calling shops in Poland. Best I've found is a shop that could resize the valve body, but don't do the pumps. The price for machining the valve body is way more than if I would buy all the valves including necessary reamers from Sonnax or a complete, remanufactured unit with performance upgrades installed. Just LMAO.

 

OK, so first thins first.
How is the Sonnax pressure testing device work? By looking that movie:
I've figured out it has a following setup:


Left to right: vacuum supply -> manometer (unfortunately I have to convert from Hg to bar and vice versa) -> valve for calibrating -> measuring plate
Total cost: $12 (not including the gauge I already had).
Adjusting procedure:

• shut off the flow at a probing plate
• adjust the calibration valve to get -25Hg (-0.85bar). The ambient flow to a vacuum pump is required to make the measuring method time independent (as on the picture above)
• open the flow from the probing plate

Measure the pressure:

Read the indication:


So, in my case, the pressure regulator valve builds up to -0.45bar, which is approximately -13,3Hg.
EDIT:
Sonnax has published a nifty PDF pointing the 4L60E vacuum test points(https://d2q1ebiag300ih.cloudfront.ne...f?v=1526932555)
Following the diagrams:
TCC apply valve: -19,2"Hg (18"Hg nominal) OK
Pressure regulator -13.3" Hg (18" Hg nominal) Worn
Boost valve -21.5"Hg (18"Hg nominal) OK

Now I know where I am at.

 

Bravo!!

 

So the current status is:
I have to machine the pump body to use an oversized pressure regulator valve from Sonnax. Exactly like Transman304 said - it will be worn. The OE diameter is 0.365, it has to be machined to 0.375 (thanks Transman304!). I failed finding a shop that could do it for me in Poland, so I've:
- ordered a .375 reamer from US. It's mount is 5/16", so I've
- ordered 5/16 drill that is going to be used to fabricate the reamer guide
I am hoping it is going to work. I'll continue as soon as I'm done with the pump assembly.
Meanwhile I've got the assembly lube (locally) and collected a parcel with sprags: