I am currently rebuilding my 4L60E and I am at the point where I am checking Dimension D of the Lo/Reverse clutch Stack-Up from the ATSG manual. I am installing an Alto High performance Clutch kit. This kit comes with 5 frictions and 5 steels. No selective plate. When I do the stack up with the 5 frictions and steels the Dimension D comes measures around 1.18 instead of the 1.2 to 1.24 spec'ed out in the manual. Interestingly enough the trans has been rebuild at some time previously and the exact same set-up came out of the lo/Reverse clutch. The trans was being rebuilt because from 2nd to 3rd it would not engage and then slam into 3rd. I found broken teeth on the input drum above the snap ring that holds the 3-4 clutches so I am assuming this was the issue.

The original Lo/Reverse clutches and steeles looked to be in good shap with no signs of slipping, so the trans is going back together today under the assumption that this is OK and the Lo/Reverse piston will make up for this.

But it's not too late, so if I am making a big mistake please let me know. If I order the .090 selective plate it will put me just outside of the acceptable range.