Adapting the
GM 4L60-E (later version) Transmission
to the
Jeep Dana Model 300 Transfer Case and
Full-Size Jeep New Process Transfer Cases
Our 4L60-E (including the 4L65 & 4L70) to the Jeep New Process (or New Venture) transfer cases conversion makes for the most refined assembly both on-road and off-road, and has become one of our most popular transmission to transfer case combinations.
|
||
The adapter kit is designed for compatibility with the Jeep Dana 300 transfer case.
The Adapter
The Novak 4L60-E to Dana 300 transfer case adapter is very compact at only 3.0" long for a combined transmission and adapter length of 24.5" (equivalent to a 17.5" manual transmission). The adapter itself is cast and machined of a high-grade aluminum alloy, featuring thick flanges, a heavy cross-section and strength-adding gussets.
4L60-E Versions
Any versions (2wd or 4wd) and year of the HydraMatic transmission can be adapted to these transfer cases. There are no inherent advantages to the 2wd vs. 4wd transmission.
These kits are for the hexagonal, six-bolt tailhousing 4L60-E, typically made starting in 1996. Some 1997 and earlier versions have a four-bolt pattern tailhousing and non-removable bellhousing. See our Kit #137 if this describes your transmission.
Transmission Output Shaft Replacement
Every #4L63 kit comes with a new output shaft for the 4L60-E, whether for 2wd or 4wd transmissions. 2wd versions work equally well as 4wd versions. The Novak output shaft is of an alloy steel, precision splined and hardened for a superior interchange. This shaft connects the 4L60-E output directly to the existing 23 spline Dana input shaft for the strongest combination available.
Installation requires disassembly of the transmission main assembly, and we recommend the services of a transmission professional, though good work is within reach of the home mechanic. The basic installation is 3-4 hour bench job and may include simple gasket and seal replacements. Some choose this as the time for a more thorough master rebuild and update if necessary.
Vehicle Speed Sensor
The Novak adapter assembly integrates the Vehicle Speed Sensor (VSS) necessary for the operation of the 4L60-E's computer. This greatly simplifies the installation process and eliminates the need for a transfer case range switch circuit and logic, making all GM 2wd and 4wd engines, transmissions and their PCM's great candidates for the installer.
 |
||
The Jeep speedometer cable or VSS can then be connected to the Jeep speedometer or gauge panel as per factory.
Transmission Rear Mount
This transfer case adapter's design is ready to accept our industry standard urethane isolator mount, available for purchase. This is our preferred rear mount unit. Our kit is designed for it, and its usage is essential to protect powertrain components from the flex and jar typical of any automobile, but especially Jeeps.
Whether you are assembling onto a stock cross member / skidpan or if you are setting up a high-clearance skid plate, you will find it to be a clean and simple process.
Transfer Case Clocking
Our adapter is optimally clocked for your Dana 300, such that it will be nearly flat, for the best possible ground clearance.
 |
| Twin sticks are a good idea, especially considering the improved clocking of the 300 with the new adapter. |
Transfer Case Shifter
This transmission conversion will allow for the retention of the factory shifter (with some bending mods to the stick), or allow you to upgrade to a twin-stick kit for advanced transfer case operation and better tunnel port interaction.
Transmission Shifter
A broad variety of transmission shifters are compatible with this conversion, ranging from console shifters (i.e.; Art Carr, B&M, etc.), to direct-mount stick shifters (i.e.; Gennie, Lokar, etc.).
 |
| The Lokar direct linkage transmission shifter offers a smart method of shift operation, especially for installers replacing a Jeep manual transmission with the automatic where use of the factory console and boot will contribute to a clean installation and a very factory look. Image courtesy of Lokar - TH350 shown. 4L60-E shifter similar. |
Driveshafts
Use the factory diameter CJ front driveshaft (typ. 1-1/2") to acheive transmission pan clearance.
Driveshaft length changes are sometimes required, as this geartrain combination is typically shorter than most factory Jeep combinations. Some potential conversion engine installations sit further ahead than OEM engines in the Jeep's bay and will allow for better driveshaft angles, especially when done with this very short combination.
Some of our customers, fearful at the perceived expense of new or modified driveshafts, attempt to let the existing driveshafts dictate engine, transmission and transfer case location, sometimes to the detriment of the project. Driveshaft modifications are usually inexpensive when performed by driveline, RV or tractor implement specialists. New driveshafts are an option but seldom a requirement in regards to the actual successful conversion. Jeeps that require extensive travel or specialty-built driveshafts have this option available through several fabricators across the nation.
Transmission Cooling
For every 10 degrees cooler you can keep the transmission, you can add 25,000 miles to its service life. Therefore, use of a transmission oil cooler is advisable for this automatic transmission.
Use of a transmission temperature gauge is also a good idea. These are widely available and generally inexpensive.
With the increase in popularity of the newer, hotter burning, fuel-injected engines, it is increasingly wiser to run a stand-alone, dedicated transmission fluid cooler.
Engines & Engine Mounting
A 4L60E installation is typically done in conjunction with an Generation III GM engine conversion into the Jeep. These engines include the Chevrolet Small Block V6 & V8, from 1996-2006. Though Gen. III installs are much more prevalent, Gen II and Gen I motors installations are possible but will require the use of a separate transmission computer controller which may add significantly to the expense of the total installation.
 |
| Novak's MM Series engine mounts, featuring excellent vibration dampening, superior strength and impressive adjustability - adjustable even after the engine is installed. The design, strength and affordability of our mounts are second to none. |
Novak offers what we have found to be the most intelligent engine mounting system for Jeeps available, allowing the installer to make an easy and satisfying decision as to powertrain placement with the 4L60E and the Jeep transfer case both considered.
 |
| Advanced computer modeling methods were itegral to the design and manufacture of our #4L63 adapter assembly. We were able to push the bounds of product and process well beyond the status quo. |
Axles
Use of factory axles is completely acceptable with this conversion. Axle upgrades are not necessary, but they may be chosen for reasons external to this transmission upgrade.