Questions on 4L60E to 4L80E swap.

[ResourceReaper]

kewljay, I cannot thank you and everyone else here enough. It almost is looking like this is something that I cannot do in a weekend. So here is where I am.

They did make a (get this) 2005 Silverado 1500HD which had the 6.0L and 4L80E engine. But I'm not finding anything on the transfer case that was in there. I'm still researching though.

I found a j/y trans for $750. I figured that I might as well completely replace the transfer case with a new one (it's 225K on the truck... I think it might be time). It never dawned on me to see if they made a manual transfer case for the 2500HD since mine is a manual (floor mounted) shift, which I have to be honest, I prefer. I guess does it matter? If the 80E's transfer case is only electric motor driven, how much work is it to wire up the dash selector switch? I think (hopefully) this is one of the last questions I'm going to have until I start buying stuff. To solve the drive shaft issues, I'm going with a new drive shaft from Denny's. I want to go with a new yoke, front and rear shafts.

[ResourceReaper]

Someone used to make an input gear for the tcase but last time I spoke with him he was making them in group orders only.
We have used them several times. Just disassemble the tcase and install the new gear.
The tcase will now accept the larger output shaft of the 80e.
You may need the case housing or tailshaft if its called for the trans as well. Can't Rememebr. Thinking the number of bolt holes are different. The piece that sits between the trans and tcase

The 80e write needs updating. Fewer parts are needed and there are various methods to accomplish the conversion.

You wouldn't be able to tell me who would you?

[MrHorsepowerLSx]

If you have a manual transfer case, look for the same transfer case in the 2500 trucks, stay away from the "higher end" trucks, they will come with the push button transfer cases, and a 2500hd floor shifted case should line up with the hole your 1/2 shifter was in,look at the base models, and work truck versions for your swap, don't bother "looking" for the " auto-trac" versions they will only complicate your swap with more wires and you will still have a hole in your floor to deal with. And yes the rear end yokes are different on a 2500 rear then the 1/2 ton trucks. And just swap your yokes and u-joints around an then get it shortened if need be, and then balanced.