howard quick

Very common for this retaining clip to break.



There's an item available called a 'transfer case saver' which would be a good upgrade whilst in there.

http://www.drivetrain.com/gillies/Tcasesaver.html

I had the machinist at my work make one for me.

KySilverado

iTrader: (7)

Yep figured out the shift cable bracket last night. It's now on the list of needed parts. I also looked at the wiring and can re-wire to use the 80e neutral switch but you are right probably best to just use the 60e. Wonder why they changed them?

Thanks so much for the assist. I've got your transfer case photobucket url saved. Didn't know you'd done the 60-80e photo shoot. I think I have a pretty good understanding of that part. I see 2 ways guys are modding the crossmember. Cutting the entire center section out and moving it back or just welding on a bracket on the back.

I'd seen your post about the case saver. Is this for the pump wear through of the case? Probably should pick up a couple of those c-clips.

Thanks again for the input.

howard quick

That retaining clip breaks and that allows the shaft to wander.

As for the crossmember....mine bolted straight back in with no modifications. I did have some sort of adaptor in there for the 60E...from factory. I just removed that and the 80E bolted straight to the crossmember.

KySilverado

iTrader: (7)

Ah, so you weren't warning me that I might break the clip during the teardown of the case for input shaft swap, but that it is a weak link in the case design and breaks during operation.

Rafedial

iTrader: (7)

my '04 Z71 is very similar to yours. I have a 4L80E on the way to do the swap myself since my 4L60E failed. Where did you find that input shaft? and can anyone else confirm the part #?

The current driveshaft in my truck is also one piece aluminum and most places have problems with modifying due to the length and material. Would it be better to use a 2 piece steel shaft and weld in the carrier bearing support for it, then shorten it??? Any other options?

KySilverado

iTrader: (7)

http://www.tbtrans.com/transfer_case.htm

Yes the drive shaft will be a problem. I personally do not want to do steel shafts or 2 piece. I am betting there is a one piece GM drive shaft out there that will drop in. Possibly changing yokes somewhere. I've been looking for a complete list of DS specs for the various NBS GM platforms to no avail.

Breeze had a long one piece made somewhere.

howard quick

That's correct.

I have a steel driveshaft in mine. Had to get it shortened 42mm.
The front drive shaft should not need altering.
Some guys have had to grind the splines down a little where it comes out of the front seal....but I didn't find this necessary. It deffinately doesn't need to be lengthened.

Rafedial

iTrader: (7)

The transfer case input shaft for using Autotrac+4L80E in a Nbs 1500 4WD is Gm Part #12386258 superseded by current part #88962329 for $40 more, GM p direct. Still need to confirm before I order...

Breeze

iTrader: (16)

A-1 Driveshaft here in Md, I swear they balanced it better than the factory Ds

KySilverado

iTrader: (7)

Steel or aluminum?