pics of my sy #2695

choffert1

choffert1

New member
Re: pics of my sy #2695

While the engine out been busy with some other things on the Sy, so here is some up dates. I removed the fuel tank and replaced the fuel pump with Areomotive stealth 340 pump and I repainted the tank. Also replaced the lower column bearing with the new gm bearing and adapter. I received a bunch of parts back from powder coating and ceramic coating. Finished the final assemble of the turbo.
















 
choffert1

choffert1

New member
Re: pics of my sy #2695

Finished up a couple of smaller projects I've been working on and off for about a month. Polished the Intercooler pipes, replaced both front axle seals and cleaned up the front diff again.





I'm also converting over to AN hoses and was trying to come up with a plan on what to use for the oil cooler line fitting in the radiator. I found that the fitting uses a 20x1.5 thread, but there is nothing I could find that size with a o-ring like the factory. I found a fitting made by Fragola p/n 461008 it is a -10an x 20x1.5.


The fitting mearsures on the inside .461" so I drill in about a 1" in with a 31/64 drill bit to get the size right to .486"



I measured the diameter of the facory oil cooler line and it was .491". That will give me .005" of interference fit. I also installed another o-ring seal on the side that mates up with fitting just in case.



Here is the final product.



Test fit in the radiator and fits like a charm

 
choffert1

choffert1

New member
Re: pics of my sy #2695

Pulled out the transmission and t-case as a unit it's really easy when the engine is out. Also picked up a few more fittings and a new fuel filter with -8an fittings. Then I installed the new fittings on the fuel sender.



 
choffert1

choffert1

New member
Re: pics of my sy #2695

Didn't do much this weekend just mounted my RPM fans. Also removed the wiring for the intercooler pump, factory boost solenoid and the egr.

 
Sean Krupa

Sean Krupa

Moderator
Re: pics of my sy #2695

Chris,

Since I'm not using the oil cooler side of my radiator, I want to plug the two spots so what plug size should I be looking for to fit into the radiator. Just don't want to leave the holes open.

Thank You,
 
choffert1

choffert1

New member
Re: pics of my sy #2695

Made a little progress this week and I finally got my engine back from Moretto Motorsportz and it is sweet. What a bunch of great guys at their shop!

Also ordered the rest of the parts I needed to rebuild the 4l80. Torqued converter should be here Monday. I went with a Circle D 258mm multi disk 2800-3000stall

Install the speed inc 4l80 input shat into the t-case and cleaned it up and hit it with some fresh paint.
before



after



Had Moretto open up the intake to 58mm


The engine


The engine painted
 
I

INDYZD

New member
Re: pics of my sy #2695

Awesome work on the truck looks great.
Where are the side mirrors from? I read through the post and only reference I found was SS mirrors.
We're they direct bolt on or mods needed?
Color looks better on the sy than on my buddies Tacoma.

Cheers
 
choffert1

choffert1

New member
Re: pics of my sy #2695

INDYZD said:
Awesome work on the truck looks great.
Where are the side mirrors from? I read through the post and only reference I found was SS mirrors.
We're they direct bolt on or mods needed?
Color looks better on the sy than on my buddies Tacoma.

Cheers
Click to expand...

Thanks for the kind words. The mirror are from a company called Street Sense. They are not a direct bolt in and will need a small amount of modding to install.
 
Quickstop [UK]

Quickstop [UK]

Combating adversyty.
Re: pics of my sy #2695

Incredible attention to detail here.

May I ask what prep you did for the transfer case prior to paint and also what paint was involved? Also, with the 80e you picked up, what do you plan to do to it before it goes in?

That sucks about your engine. Hope you get it fixed soon.

:tup:
 
choffert1

choffert1

New member
Re: pics of my sy #2695

Quickstop [UK] said:
Incredible attention to detail here.

May I ask what prep you did for the transfer case prior to paint and also what paint was involved? Also, with the 80e you picked up, what do you plan to do to it before it goes in?

That sucks about your engine. Hope you get it fixed soon.

:tup:
Click to expand...

For prep on the t-case I washed it with some degreaser then soap and water. Then I let it dry then sanded with a red scotch brite pad. I primed with vht flame proof flat black and painted with cast iron(color) engine enamel paint and finished off with a clear coat. I'm not super happy with the color. The cap indicated color was not even close to what the actual color is, so I will be changing it to a midnight grey metallic.

As for the plan on the 80e it is getting a bunch of performance upgrades, such as red Alto clutch packs in the forward, direct, intermediate, low/reverse, and the overdrive clutches and every clutch pack will have one or more clutches and all new kolene steels. It is getting a new billet forward hub, billet input shaft, 34 tooth sprag, carbon fiber band, shift kit, all new bushings, seals, apply pistons and gaskets. Also installing the Circle D converter and will be controlling it with a pcs tcm 2000 and harness. Still debating which pan I want to use might use a Mag-Hytec.

The engine is like brand new and better than before thanks to Moretto Motorsportz.
 
Last edited:
choffert1

choffert1

New member
Re: pics of my sy #2695

A little progress made engine is almost ready to drop in. The 4l80 rebuild is under way.











The rebuilt pump


Some of the transmission parts

New plantaries and billet input shaft



The forward clutch with billet steel drum and red alto's





Cleaning the case and prepping for paint









Case all painted and ready for the internals. Still waiting for some thrust washers and bearings. I also have finished the direct clutch, overdrive clutch, and overrun clutch. Still need to clean the valve body and install the shift kit, but it's progress.



 
Z SKI

Z SKI

Donating Member
Re: pics of my sy #2695

Looking good brother... Watch the straight fittings coming out of the oil cooler adapter... I had my hose fittings hitting on the pan lip until I installed some 45* ones coming out of the adapter..

See ya,
 
choffert1

choffert1

New member
Re: pics of my sy #2695

Z SKI said:
Looking good brother... Watch the straight fittings coming out of the oil cooler adapter... I had my hose fittings hitting on the pan lip until I installed some 45* ones coming out of the adapter..

See ya,
Click to expand...

Thanks! I will keep that tip in mind.
 
choffert1

choffert1

New member
Re: pics of my sy #2695

Little update finally finished the rebuild of the 4l80.
Specs: 2004 4l80e
All Alto red eagle clutches and Kolene steels
7 direct
7 forward
5 intermediate
5 overdrive
Billet input shaft from PATC
34 place Borg Warner sprag
Billet steel forward hub with thrust bearings instead of washers from PATC
Transgo hd2 shift kit
All new seals and bushings
Sonnax short manual shaft
Sonnax updated rear case bushing


Don't mind the old pan just on until the trans is in the truck

Also noticed that the front coil over shock bushings basically squished out, so I got new bearings from Sportmachines and now it is way better


Since I'm using the stock timing cover with a ATI damper I had to cut off the timing pointer and I installed a new Moroso billet pointer


That's all for now but more to come life is getting busy at the moment
 
choffert1

choffert1

New member
Re: pics of my sy #2695

Had a good day yesterday with some progress install the new bell tech leaf springs, caltrac's, and Afco shocks. Also mated the t-case to the 4l80 and got it up into place, still have drop in the engine go get the fit rights do may have to lower the trans mount the t-case is up into the cab and the crossmember is not level yet still has to go up 1/2 inch so will figure that out when everything's in place.

The old leafs out

The new Catrac front bushings installed used a ball joint press worked great and installed the factory diff angle shim and a JTR set back plate.

Caltrac's installed

The rear AFCO shocks installed if you notice I also painted the under side of the cab and box with a smooth under coating and paint over top over that with satin black took a while but looks great

The transmission and t-case together for the last time don't have any pics of it in place yet

 
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