MajorVery commonTransmission

Chevrolet Silverado: 4L60E sun shell break and 3-4 clutch burn-out (GMT800 petrol V8)

4L60E sun shell break and 3-4 clutch burn-out (GMT800 petrol V8) is a very common transmission fault on the Chevrolet Silverado on the 1999–2006 cars, and we rate it major. Putting it right costs $3,500 to $6,500 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 14 documented faults on the Chevrolet Silverado.

Vehicle: Chevrolet Silverado
Engine: 4.2L / 5.0L / 5.3L / 5.7L / 6.0L / 6.2L / 6.6L / 7.0L
Years: 1999–2006
Fuel: petrol
Gearbox: auto
System: Transmission

This page covers the Chevrolet Silverado as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Chevrolet Silverado faults14 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Clutch yet. We would rather show none than show a picture of a different part.

What goes wrong

The 4L60E four-speed automatic behind the 4.8 and 5.3 V8 in half-ton GMT800 trucks has two well-known weak points: the 3-4 clutch pack, which has too little friction area and burns out so the truck slips or loses 3rd and 4th, and the sun shell, which cracks or strips its splines so the truck loses 2nd, 4th and reverse. Towing, heavy loads, big tyres and old fluid all speed it up. Once it slips it gets worse quickly and ends in a rebuild or exchange unit. Heavier 2500HD petrol trucks usually have the stronger 4L80E, which is less prone to this.

What you would notice

Engine revs flare on the 2-3 or 3-4 shift
Truck feels like it drops into neutral going into 3rd
No reverse, or only 1st and 3rd gears
Burnt smell from the transmission fluid
Check engine light for transmission ratio codes

How to check it

Where to look. Automatic transmission behind the engine; dipstick at the rear of the engine bay on the passenger side

With the engine warm and running in Park, pull the transmission dipstick at the back of the engine bay and check the fluid is red, not brown or black, and does not smell burnt. On the test drive, accelerate gently from a stop and watch the tachometer through every upshift: each change should be quick and firm, with no rev flare or neutral feeling into 3rd and 4th. Select reverse on a slight incline and check it engages promptly and pulls. Ask how often the fluid has been changed, whether the truck has towed, and whether the gearbox has ever been rebuilt, and ask for the invoice. If a workshop inspection is possible: have the transmission codes read with a scan tool (for example gear ratio error codes P0731 to P0734) and the fluid pan checked for clutch material.

Parts involved: Clutch.

What it costs to put right

$3,500 to $6,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has the transmission ever been rebuilt, and do you have the invoice?”
“Has the truck towed a boat, caravan or trailer regularly?”
“When was the transmission fluid last changed?”

Now check the Chevrolet Silverado you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in the sources below. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them.

SlashGear 'GM 4L60-E Transmission: The Most Common Problems Owners Report'
Gearstar '3 Symptoms Of A Failing 4L60E Transmission And How To Diagnose The Problems'
EricTheCarGuy forum thread '4l60e 3-4 clutch pack burned up'

Chevrolet Silverado buyer questions

Is 4l60e sun shell break and 3-4 clutch burn-out (gmt800 petrol v8) serious on a Chevrolet Silverado?

We rate it major and very common on the Chevrolet Silverado. The 4L60E four-speed automatic behind the 4.8 and 5.3 V8 in half-ton GMT800 trucks has two well-known weak points: the 3-4 clutch pack, which has too little friction area and burns out so the truck slips or loses 3rd and 4th, and the sun shell, which cracks or strips its splines so the truck loses 2nd, 4th and reverse. Towing, heavy loads, big tyres and old fluid all speed it up. Once it slips it gets worse quickly and ends in a rebuild or exchange unit. Heavier 2500HD petrol trucks usually have the stronger 4L80E, which is less prone to this.

How much does it cost to fix on a Chevrolet Silverado?

$3,500 to $6,500 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Chevrolet Silverado years are affected?

Our research records this fault on the 1999–2006 Chevrolet Silverado. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.