4L80E update

[RedHeartbeat]

This is just here for the documentation for my own bad memory so that I have a place to come back to in the future should I forget something. If this helps you, that's just a bonus.

http://www.ls1truck.com/forums/mecha...onversion.html previous install info...

First off... have I said how much I HATE UPS lately?
UPS put a sticker on my door while I was home and said they attempted to deliver my converter. I call UPS and explain and tell them I want to pick it up at the will-call door at the local UPS dock, they say fine, let us schedule that and we'll call you back within an hour. Guess what, no call, big surprise. I call back later and they say they called me but no answer, hmmmm.... where was I? Effers! I go to pick up the converter at the dock and they say I can't pick up items there. I tell them to get someone who knows what the hell they're doing there. A dude comes out, asks if I had it setup for will-call, I say yes, he asks the address, goes into a little room and comes out with it. Now how damn difficult was that?

The converter looks like good quality work, as usual and expected from Precision Industries. It came with new bolts for the flywheel, installation instructions and a guide showing where to install the new red converter limit valve spring. For some reason the page 7 instructions on their website don't match the instructions they sent with the converter, the .055 hole is missing in the new instructions.

Bought a used 2002 4L80E transmission to update the drivetrain and pulled it apart to find that the transmission had been rebuilt recently. New updates to the stock transmission by me include...

4L80E/turbo 400 34 element intermediate sprag assembly PN 34418X from DACCO/Detroit transmission supply. $55.04 + tax = $59.58
4L80E-HD2 Transgo Shift Kit Transmission Parts Online at Wholesale Prices!
48MOD Vacuum Shift Pressure Controller to replace the electronic module Transmission Parts Online at Wholesale Prices!
3600 RPM Precision Industries Vigilante 9.5" Converter with LS1 type front cover Finish Line Transmissions | Performance Transmissions | Torque Converters | Transmission Parts | Transmission Service
#3XX cast aluminum high capacity transmission pan 700R4, 700 Raptor Transmission from PATC, 700R4 4L60E 48RE 4L80E
National Seal rear seal #9449 O'Reilly Auto Parts - Results for Shopping Search
National Seal pump seal #4598 O'Reilly Auto Parts - name brand and discount automotive aftermarket parts, tools, supplies, equipment and accessories
Transmission Filter TF304 T709 Champion Laboratories, Inc. AutoZone.com - Get in the Zone!
or Transmission Filter WIX 58836 O'Reilly Auto Parts - Home
X-long MOROSO transmission dowels 37932 #40D 700R4, 700 Raptor Transmission from PATC, 700R4 4L60E 48RE 4L80E
#16CLF transmission cooler line fittings 700R4, 700 Raptor Transmission from PATC, 700R4 4L60E 48RE 4L80E

FROM WWW.BULKPART.COM
34300EW Pan Gasket: 4L80E (except JAGUAR) 1 $23.59 $23.59
84379 Seal, 440-T4 / 4T60E filter Seal, 1983-UP 1 $0.63 $0.63
34380E O-Ring, 4L80E Turbine shaft 1 $0.46 $0.46
34312E O-Ring, 4L80E Pump BOLT 8 $0.54 $4.32
74311 O-Ring, 700 / 4L60E / 4L80E, Pump 1 $0.85 $0.85
34310E Gasket, 4L80E Pump cover to case 1 $0.70 $0.70

Installed the full Transgo HD2 per instructions with all shift firmness settings at the maximum settings.
Step 1.
Drilled the 3/16" hole
Step 2.
Installed the one inner BLUE Accum spring by itself for even firmer shifts. Replaced stock plug with new grooved/oring plug.
Step 3.
Removed oring from Actuator filter. Installed new tapered plug with oring to block off the filter passage. Re-install the filter, new orange spring inside the filter and new end plug.
Step 4.
Drill new 3/16" hole in valve body for pressure relief.
Step 5.
Assemble the relief assembly per instructions.
Step 6.
Drilled the Transgo HD2 valve body plate to .120 for firmest shifts
Install the new white spring into the 3rd accumulator piston bore
Install the check ball into the transmission body, 7 per instructions but they left out the 8th one which is the reverse clutch fluid circuit and I put it back in for a total of 8 balls.
Step 7.
Replaced the stock bushing, boost valve, washer and spring with the large purple spring from the 48MOD kit and the red bumper spring from the PI Vigilante converter kit. The pump had the Type 2 PR plunger.
Step 8.
Installed the new stronger 4th bolt
Step 9.
Installed the hollow sleeve over the 1-2 servo pin
Step 10.
Replaced the stock orange 1-2 Accumulator spring with the orange spring in the HD2 kit

Internal upgrades.
Removed front pump, input turbine shaft assembly, 4th clutch pack bolt inside valve body area, remove 4th clutch pack and direct clutch drum. Compress the spring pack and remove snap ring to remove the spring pack. Seperate the springs from the retainers and replace the 16 springs with the ones from the HD2 kit.

Remove the direct clutch drum band clutch. Remove the intermediate snap ring in the case and replace with the new thicker snap ring.

Disassemble the front pump halves and drill the hole behind the front pump seal to 1/4" through the existing casting to the internal passageway. Through the rear half, drill a 3/64(.042-.055) hole in the pump stator side per instructions. Reassemble the halves using a large diameter hose clamp around the halves to align them when you re-assemble the pump.

Drilled .055" hole at location specified on page 7 in the Precision Industries online manual Photos



Used the 48MOD shift rod at stock length 1.405 for manual shifts
Remove the stock pressure control module from the valve body and zip tied it up inside the transmission to stop any code feedback from PCM. I could have just turned the codes off in the PCM with HPTuner software most likely.
Drilling for the 1/8NPT fitting in the location specified by the 48MOD kit is not possible, drill in the corner to avoid the bosses cast into the newer style casings.