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4L80E swap on a 2004 Denali 2 speed tcase BW4482

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Old 07-11-2019, 08:42 AM
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Default 4L80E swap on a 2004 Denali 2 speed tcase BW4482

Hey guys, im in desperate need of some help. I built my buddy a iron H/C/I N2O Yukon Denali. I also built him a 60e but we've blown it up a couple times, so now its time to go 80e. Im no noob to 4x4 80 swaps, but this time around the truck had a BW4482 Borg Warner 2 speed/ AWD transfercase, i dont think GM makes an input/planetary for this application and a 80e swap. Here are some pics, if anyone has ran into this, your help would be greatly appreciated. Im thinking my only option is to have the input with the planetary machined to accept the larger output shaft of the transmission.



Last edited by Venomous281; 07-11-2019 at 08:50 AM.
Old 07-11-2019, 02:01 PM
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probably wont find one, i think the newer h3 used a 4494 transfer case but still had a 4l65 transmission.

the 6l80 and 4l80 share the same sized input, if he's not stuck on having two speed the 4485 that comes behind a 6l80 in escalade/denalis will mate to a 4l80
Old 07-11-2019, 07:37 PM
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You would need to have that resplined.

You may want to reach out to Time To Kill on here and see if thinks he can have that done for you.
Old 07-15-2019, 08:13 AM
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The 08-09 H2 came out with a 6L80E. i picked up one of those transfer cases over the weekend in Mexico. It looks exactly the same. just with a 32 spline input, even uses the same encoder motor.
Old 05-30-2022, 09:15 AM
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Originally Posted by Venomous281
The 08-09 H2 came out with a 6L80E. i picked up one of those transfer cases over the weekend in Mexico. It looks exactly the same. just with a 32 spline input, even uses the same encoder motor.

Did it end up working? Im at a stand still with my tahoe with a 6.0 4l80e and bw4482
Old 01-27-2024, 06:48 PM
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Originally Posted by Venomous281
The 08-09 H2 came out with a 6L80E. i picked up one of those transfer cases over the weekend in Mexico. It looks exactly the same. just with a 32 spline input, even uses the same encoder motor.
Well? What's the word? Hoping it worked for you. If so I'll try it in my 44-82
Old 01-27-2024, 07:18 PM
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Old 01-28-2024, 01:32 AM
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Originally Posted by 1FastBrick
That sure ain't nice...any others that may have mentioned such thing buddy? Really dont want to swap the 80e output shaft..
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