Pretty much just starting. Gathering parts. I'll update the thread as I go along. I'm swapping to 6.0L LQ4 should apply to all 4.8L and 5.3L LSx style engines. Along with and Auto Track NVG/NP 246 RPO NP8.

Parts/mods needed as I know them so far. I'll update everything with part numbers if I purchase them and know they work.

4WD 4l80e trans - has short output shaft and adapter for transfer case.
4l80e torque converter
Bell housing cover
Dipstick tube
4L80E flex plate
Crank to flex plate spacer and the longer bolts
Wiring mods to the main transmission connector (pigtails can be bought)
Extra speed sensor connector, wiring and pins to connect to the PCM
32 spline input shaft for the transfer case. (you can swap output shafts in the transmission)
Tune with 4l80e segment swap written to PCM after the swap.
4l80e transmission cooler lines or modify what you have
Modified transmission cross member.
Modified/New Driveshafts - Rear shorter - Possibly front longer

 

ill be following this, your doing the different output shaft vs changing the input gear on the t case? wouldnt this still be the weak spot then?

 

The transmission: Purchased from e-bay. Listed as an 05 4WD with 6K miles. It came with a TC. I paid $1073 shipped to a nearby Fedex Freight terminal. Drove there and picked it up.



Little bit of cleaning.


Got it to an engine stand and unbuttoned it in preparation for a Transgo HD2 install. Looks like a brand new transmission so I'm happy with it so far.

 

I will be swapping out the input shaft in the transfer case. From the 27 spline to the larger 32 spline to match the output shaft of the 80E. Already ordered this part.

 

The 80E has 2 speed sensors in it. The 60E only one. You have to get it connected to the PCM. The connectors and pin outs is pretty well documents here. I won't go into that. I'll show you what I did for it.

Happened to have the old battery acid eaten wiring harness that came on my junkyard 6.0L when I did that swap. It happened to be an 80e harness.



I dug out the connector, wiring and PCM pins from the harness. I'll wrap these up in thier own protector and run them to the PCM. Main reason I did this is now I won't have to round up the PCM pins.

You'll connect the new sensor to PCM via PINS 22 (RED) and 23(Blue). Just as this 4l80e harness is wired.




I also removed the 4l80 style main connection from the old harness in case it fits in better than the 60E connector. I've seen you can buy these cheap on e-bay. I've not read that this is necessary but might install a little cleaner.


Circled the VSS sensor I'm talking about that has to be wired up. The other will be in its original location on the end of the transfer case.



I also want to note that connectors on these things are modular. I was able to dismantle the PCM connector to get the pins out easily and I also dismantled the VSS connector and swapped out the connector because a snap was broken on the old 6.0L VSS connector.

 

 

The inside of your truck's box is way too shiny dude. Better let the old tranny roll around, beat it up, and puke some fluid out when you haul it away.

 

Just documenting all the parts I have so far.

Picture of the stock 80E Torque converter, flex plate side. Course the signature 6 bolt to the flex plate vs only 3 for the 60e. Which reminds me that I need get some TC bolts. Right now I am planning on getting a PI converter.



Happen to also have a 6.0L flex plate from my engine swap. I kept it for just this occasion. Course it has the spacer on it also. I've got a TCI SFI plate on my 65E that I'll wind up selling. Not going to do an SFI plate with the 80E. Going with this stock plate.

 

Chances are any 80E you get will have a different neutral safety switch on it. This is a newer style I believe. Some of the older have two connectors in it. Anyway you should be able to just slide your current NSS on and go. If I can figure out the wiring I am going to swap to this one. My current one has been on and off several times and is a bit sloppy on the shaft and the first time I removed the transmission in the truck I like to have never gotten the thing unplugged and buggered up the connector on it now.

 

I still use it as a truck and always have. It is scratched up and dented a bit. I do try and take care when hauling things though. Notice the blanket under the skid with the tranny on it. I am a bit embarrassed to say that I regularly wash the truck box. Might even paint it back up soon. **** I know