4l80e Help

George Blake

DONATING MEMBER
Re: 4l80e Help

I saw the stuff posted that you had problems with. The trans isn't the first and I can understand where you would be burnt out. I don't think your blaming me. But I can't help but be upset it happened. From now on all of the PG shafts will have a number engraved into them that will be kept on file. If someone buys a kit from someone and sends it to me for install, if the number is not there, I won't use it. Or if it has a number that is NOT on file, I won't use it. Same with the adaptor plates. This will NOT happen again.
Gilberts have always had clearance issues with the manual shift lever. I'm gonna correct that also. The solid engine mounts that are out there move the engine and everything else UP. It realigns everything. I wish they could make engine mounts solid that sit DOWN where the stock ones do. It would help with the downpipes and everything.
Everyone doing 4L80e swaps from now on should just go ahead and notch the pinch weld at the top. On the transmissions I will trim the rib down in that area also and clean it up before it gets bead blasted. That way all the other trimming I do will blend right in. Yes, I trim the crap out of the cases for clearance. I'll do the cases at the top too but the firewall will still be to be notched at the pinch weld.
Hopefully Frank will put up some pics of that.
Kits in the future will include engine bolts. 3/8" corse thread 5 1/4" long for the extended bolt at the transfer case brace.
I'm trying to make the kit as complete as possible and pass along vendor discounts I get to everyone. Because I put it in a kit, the individual prices aren't advertised and I don't get in trouble with manufacturers that way.
The manual shaft lever will also be on there. I will do a fix for that as well in the kits. It just makes the price go up a bit but will be worth it to save the headaches. Your putting in a trans built to go in 3/4 full size trucks, RV's, and buses. I'm doing everything I can to make it as friendly as possible to go in but every truck has different mods and GM did them all different so problems may vary and I can't account for all of them. I'll do my best though.
 
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gjp

another post whore
Re: 4l80e Help

most was just questions because I have never done this before. This is the first time I have to remove something I spent 2 weekends installing.
 

George Blake

DONATING MEMBER
Re: 4l80e Help

Don't take the trans out. Just get the crossmember out. I know you don't have tons of tools but get the crossmember out. Much easier than the trans.
 

gjp

another post whore
Re: 4l80e Help

I have to order a torsion unloader tool. No one localy has one.
 

MRKING

New Parts for Old Trucks
Re: 4l80e Help

That output shaft was from a Js kit that was made back when turbotime was still selling Js products .
 

gjp

another post whore
Re: 4l80e Help

george can I rent the unloading tool from you. I cant find one localy to rent. Even summit or jegs.
 

WyoSyclone

Active member
Re: 4l80e Help

Wow, I feel sorry for both Gary and George - both guys trying as hard as they can, and being bitten by the SyTy gremlins! But, you guys are both awesome in the way you're dealing with a trying situation :tup: :tup: to both of you!

I swear Gary if I was even halfway close to you, I'd come help. I think we can all feel your pain :banghead:
 

MRKING

New Parts for Old Trucks
Re: 4l80e Help

If you put a 3/8 drive extension on a floor jack and apply lifting pressure to the inside of #186 from the pic george posted above , it will allow you to unbolt 184 and slip 185 out of the way . Then let the jack down slowly so you can remove the torsion bar . Easy to do .
 

gjp

another post whore
Re: 4l80e Help

MRKING said:
If you put a 3/8 drive extension on a floor jack and apply lifting pressure to the inside of #186 from the pic george posted above , it will allow you to unbolt 184 and slip 185 out of the way . Then let the jack down slowly so you can remove the torsion bar . Easy to do .
Thought of doing that. Just not sure how much pressure its under. Might as well buy new stuff while I am at it. WHere to find what I need and what should I replace.

Try that tomorow. I had a few shots. Few to me is 5-6 and shots is Tequila. is there a cheap coil over that uses stock arms?? Cheap I mean under 600$.

Sorry to upset your george. I know these trucks are unique and doing this conversion was not easy. Problems arise. Just when I got this truck last year I was wanting more driveing then this. I always wanted a sy. Remember I had a gt for 12 years. just want to say sorry to the syty commmunity for my rants. Just another bad day in my life.
 

gjp

another post whore
Re: 4l80e Help

now the big question. What kind of damage did this do to the TC.
 

autoaddictions

Active member
Re: 4l80e Help

Hang in there gary!!! I know it sucks just get your ass under there and do it.

I can say this is the hardest days work ive put in for a while. I removed the trans cut 3/8 of the output shaft reinstalled everything. Im done under the truck now Fuel lines,treans,propshaft, rear drive shaft, trans cooler lines, shifter linkage and cables 4 big stuff trans control. I took some picks of the jobs inhand.

1st a note on the crossmember there seems to be some confusion here. My TY has 2 crossmenbers in the middle of the truck. 1 of them holds the torsion keys and bolts in with 2 bolts on each side. Then there is a larger crossmember spaning from left frame rail to right. This crossmember is riveted at the top and spot welded at the bottom as well as one of the bolts from torsion member goes threw aslo. Basicly the torsion member sits inside the bigger one!
You can see the right side rivet hole after i grinded it out!


Heres the drivers side larger crossmember

Heres a shot of the hole problem needs to be 5/8 long not 1.125


heres me cutting off 3/8s of an inch!!

The piece i cut off next to a 25cent

Heres the spot to smash the pinch weld at top of trans tunnel for more clearance!

After i cut the shaft the transfer case went back together without forcing it closed and the trans turned with no problem. Here a short video
Click here to watch turning-propshaft-ouput
 

gjp

another post whore
Re: 4l80e Help

Well I am half way there. I wish i had a setup like you. I did this while the truck was on 6 ton jacks. Used a jack with a puller to remove the bars. BTW they slipped off. Got to love a nevada truck. No rust! Then I was able to use a sawsall and cut the rivit off the pasanger side. Dremel it flush and drilled it out. Used my anger to bend the larger crosmember back and forth till the weld broke. With one side lose I was able to swing it out the way to remove the TC. Forgot it was full of fluid. Yuck! Still a bit drunk. My shaft is not as bad. Just over 7/8 an inch. Guess thats why mine would move but was hard. As for selling the truck....I am stll thinking about it.
Picture1630.jpg
[/IMG]
Picture1631.jpg
 

gjp

another post whore
Re: 4l80e Help

George Blake said:
I saw the stuff posted that you had problems with. The trans isn't the first and I can understand where you would be burnt out. I don't think your blaming me. But I can't help but be upset it happened. From now on all of the PG shafts will have a number engraved into them that will be kept on file. If someone buys a kit from someone and sends it to me for install, if the number is not there, I won't use it. Or if it has a number that is NOT on file, I won't use it. Same with the adaptor plates. This will NOT happen again.
Gilberts have always had clearance issues with the manual shift lever. I'm gonna correct that also. The solid engine mounts that are out there move the engine and everything else UP. It realigns everything. I wish they could make engine mounts solid that sit DOWN where the stock ones do. It would help with the downpipes and everything.
Everyone doing 4L80e swaps from now on should just go ahead and notch the pinch weld at the top. On the transmissions I will trim the rib down in that area also and clean it up before it gets bead blasted. That way all the other trimming I do will blend right in. Yes, I trim the crap out of the cases for clearance. I'll do the cases at the top too but the firewall will still be to be notched at the pinch weld.
Hopefully Frank will put up some pics of that.
Kits in the future will include engine bolts. 3/8" corse thread 5 1/4" long for the extended bolt at the transfer case brace.
I'm trying to make the kit as complete as possible and pass along vendor discounts I get to everyone. Because I put it in a kit, the individual prices aren't advertised and I don't get in trouble with manufacturers that way.
The manual shaft lever will also be on there. I will do a fix for that as well in the kits. It just makes the price go up a bit but will be worth it to save the headaches. Your putting in a trans built to go in 3/4 full size trucks, RV's, and buses. I'm doing everything I can to make it as friendly as possible to go in but every truck has different mods and GM did them all different so problems may vary and I can't account for all of them. I'll do my best though.

Yes, this was a pain in the Ass. But there was no fault to anyone. I just want to say George has been great throughout this project for me. He is one of the best venders here and a great guy. He has helped me beyond what a seller should. This was a fluke thing. Have to expect that from not only syty's but also trying to shove a big trans in a truck thats tight to begin with. I have learned so much from him and this site. I only hope this experence helps fix some of the issues with this instal and soon the install will be as easy as swaping a stock trans. Its great to see George is only making his kits better and more complete. Hats off to you!! If you buy from George, you not only get a good product, but his support is top notch. Thanks, Gary Pulizzi
 

gjp

another post whore
Re: 4l80e Help

mines done too. Had to plant some flowers for the family today so I was not able to finish the re-install. Ordered new mounts from summit too.
Picture1633.jpg
 

autoaddictions

Active member
Re: 4l80e Help

Hey george i cant find the flat clip that holds shifter cable to the js man bracket on the trans where can i get one!! An what are you talking about sending me a servo or
somthing? Im almost done the hole truck Ill be giving her a try on thursday night. Hope it starts!!
 

gjp

another post whore
Re: 4l80e Help

autoaddictions said:
Hey george i cant find the flat clip that holds shifter cable to the js man bracket on the trans where can i get one!! An what are you talking about sending me a servo or
somthing? Im almost done the hole truck Ill be giving her a try on thursday night. Hope it starts!!
good luck. I hope mine starts too. where did you tap in for the power for the trans computer? and does the cable linkage just get a clip through the hole on the arm? I dont remember if there was a washer or something on it too. Thanks
 

George Blake

DONATING MEMBER
Re: 4l80e Help

That clip was the original piece. It is the same clip used on brake line fittings and parking brake cable fittings. NAPA will most likely have what your looking for.
Yep. I got another 2nd accumulator I want to send you. I machined this one for viton D rings.

autoaddictions said:
Hey george i cant find the flat clip that holds shifter cable to the js man bracket on the trans where can i get one!! An what are you talking about sending me a servo or
somthing? Im almost done the hole truck Ill be giving her a try on thursday night. Hope it starts!!
 

autoaddictions

Active member
Re: 4l80e Help

Well it runs!! I started it up today let it run for a minute. George i filled the trans it took 7 quarts does that sound right?? I also put it in over drive and it didnt move i had to go to D to get it to move forward this is probably a shifter cable adjustment right? I dont have a cable to link my laptop to the bigstuff 3 system to see the transmission settings so mabey theres somthing there too! For some reason Mike at RPM never sent me the cable with the kit! Almost done this thing i can wait to drive it!
 

George Blake

DONATING MEMBER
Re: 4l80e Help

It's gonna take a lot more fluid than that.
You already put the rear band servo back in, right? Reverse worked OK?
The PCM runs the trans and controls line pressures. Do NOT run the trans any more until you get a correct signal going to it from the pcm to control pressures. The big stuff 3 controls 4L60e's and 4L80e's. If you run a 4L60e signal to a 4L80e trans you will damage it.
It will suck fluid out of the pan and you will have to replace it. You can't just fill it up and drive away like you can doing an engine oil fill.
You should've got your cable sorted out while you had the pan off so you could see which gear it was in and verify. Keep checking fluid and keep adding fluid until it stays full with the truck sitting on level ground. Did you get a new clip to hold the shifter cable in place underneath?
 
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