please for those of you that have done the swap like myself go ahead and add how you did yours. or ways you think work better. this may not be the best way to do the swap but this is just how i did it. i have had this done for 2 years without a single problem.
I used a 4 wheel drive 4l80e transmission out of a 2001 chevy van 2500. you can use a 2wd 4l80e transmission but you must changed the tail shaft in the transmission. because the the tail shaft for a 2wd is longed than a 4wd tail shaft. so the transfer case wouldn't bolt up because there would be a gap between the transmission and transfer case.
Heres a List a what will be needed.
4 wheel drive 4l80e transmission.
4l80e converter you can use a stock one or a customer torque converter from a after market company.
4l80e dipstick tube.
second speed sensor.
you will need a flexplate from a older 6.0 with the spacer on it 3/4 ton with a 4l80 or you can get a spacer with bolts from raptor transmissions.
modifie your factory transmission cross member or get one from a 2500hd or there are company's that make them I modified my own it was easy.
T-case shaft from time2kill
transmission cooler lines from a 2500hd or just go with flexible lines from transmission to cooler.
your driveshafts will also need to be modified. the rear will need to be shorter and the front needs to be lengthened. you could also get shafts from a 4wd 2500hd. I had my local driveshaft shop do mine. It was about $400 with new u-joints.
you will need your PCM retuned for the second speed sensor.
over all this was a fairly easy swap. I had never done this swap until i did it to my own truck. If you have basic skills you could do this yourself. if you can do a transmission swap you can do this.
Here are few questions you might ask. ill just answer them because I myself was confused before doing the swap and it all came together after I did the swap.
you might ask why do the need the t-case shaft from time to kill. well the factory 4l60e has a smaller tail shaft than the 4l80e so when you go to mount your transfer case to the 4l80e transmission it wont go together because the 4l80e tail shaft is a lot bigger and wont go into the transfer case.
the 4l80e transmission is a longer transmission so thats why you have to modifie the cooler lines, transmission crossmember and driveshafts.
The 4l60e/4l65e transmission use's only one speed sensor where the 4l80e uses 2 speed sensors.
after you have everything you need for the swap and you are ready to start the swap. you needs to drop your 4l60/4l65 out along with your transfer case.
after you have those removed you will need to do a few things. before you can go in with the 4l80e. at this time you will want to tackle the wiring part of the swap and also the flex plate.
for the wiring parts its just a matter of depinning 2 wires on the transmission harness and swapping one of them around. then you will be adding the 2 wires for the second speeds sensor.
will start with the transmission harness.
on the transmission harness. you will need to tear it down. it looks like this.
you will need to pop this is little cover deal off. like so.
the insides will look like so.
on the back side of the harness you will want to find the dark brown wire which is (wire U) in this picture then you will want to find the white wire which is (wire S) in this picture. you will need to unpin both of these wires
after getting these unpinned they should look like this.
with both of these wires out now you will take the dark brown wire that came from hole U on the harness and now install it in the hole S that you removed the white wire from in the step before this. like so
now you don't even use the white wire that you removed for the harness. either clip it off or tape it back, i just bent it over and used a piece on heat shrink and tired it off to the side
like so then i just heat shrinked it.
now just put the harness back together. your all done with the electrical part of the swap.
heres the second speed sensor part. i got my second speed sensor harness from a donor spare harness i had laying around.
for this part you will need to unbolt the plugs from the PCM. the PCM is located if the front of the truck under the hood. right below the battery on the drivers side. it has a black cover over it the pops of. there is a bolt on the center of each connecter. after you have unbolted them from the PCM you will be working with the green one. one is green and the other is blue. you wont need to touch the blue one only the green one.
here is what they should look like after unbolted from the computer.
you will want to get the little grey cover off the back of the green pigtail. the little grey cover just covers up all the wires going into it.
it should look like this.
now you will want to get the green little cover off the front of the harness. they look like this.
to get this green clip off will need a small flat head or a straight pinning tool. there is 1 little clip on each side of the of the harness that you will need to press in and the green top will pop right off.
it should look like this after getting it off.
Edited by shawnss, 04 November 2012 - 10:35 PM.