anyone have experience converting a 4l80E to full manual?

Discussion in 'transmission and Drive train' started by grumpyvette, Oct 11, 2011.

  1. 87vette81big

    87vette81big Guest

    At Eds In Joiliet Grumpy.
    We have both read that thw 4L808E is good for 800Hp & 800ft/lbs torque.
    Not sure if its true.
    I would upgrade to All parts that Sonnex & Trans Go has available to fit your budget.
    Red Alto Eagle frictions & Kolene Steels for sure.
    300M input shaft.
    Heavy Duty Sprags.
    That eats up $800-900 cash right there likely.
    Then the Torque converter.....$1500-2000 or more.
    Last edited by a moderator: Jun 2, 2016
  2. 87vette81big

    87vette81big Guest

    Cheetah Reverse Drag Race shifter is my pick Grumpy.
    At 900 + Hp you don't want to miss a Gear.
    You recall from Driving Muncie 4-speeds also.
    Balls out Flat footed on the gas pedal.
    Never lift.
    Tap the clutch & grab another gear.
  3. 87vette81big

    87vette81big Guest

    Light Switch Method Randy showed is Very Kool Too.
    Poor Man's Way I like a lot.
  4. GLHS60

    GLHS60 Well-Known Member

    The guy did a nice job of telling which light switch lights what...

  5. 87vette81big

    87vette81big Guest

    This has to be one of the Hardest Financial obstacles to overcome....
    For Chevy & Pontiac Guys..
    What to do about an Overdrive transmission guaranteed to take a true 500-550 ft/lbs to 2,000 + ft/lbs at the flywheel day in day out for years.
    Buy & Build the 4L80E trans.
    Buy the Torque converter.
    Buy the stand alone ECM.

    Talking $3,500-$10,000 cash required.

    The only inexpensive way is to run the 4L80E trans Bone stock.
    And use the light switch method.
    Take your chances as.

    Or use a Turbo 400 trans & Muncie 4-speed as I have in my Pontiacs.
  6. 87vette81big

    87vette81big Guest

    My '63 GP is the perfect car to test a 4L80 E trans.
    If I can find another for $100 or free.
    I had 2 RWD 4L80E from Chevy Pickups.
    Gave them away. Burnt up dead.
    From fleet vehicles I worken on in the past.
    The Olds 425 has Super Torque so no high stall required .
    Use the Lightswitch method to make shifts.
  7. 87vette81big

    87vette81big Guest

    I would need a Trans Adapter plate too.
    4L80E is Chevy only Bolt pattern.
    Need to adapt to BOP & Caddie V8 bellhousing bolt pattern .
  8. Grumpy

    Grumpy The Grumpy Grease Monkey mechanical engineer. Staff Member

    General Motors 4L80E

    ‘91 to ‘01 Chevrolet and GMC

    4L80E (four-speed)


    Although it’s found primarily in early 6.5L-powered GM trucks, the four-speed, lockup 4L80E automatic wasn’t designed specifically for diesels. Despite this, the 4L80E is still a very strong transmission.

    The transmission benefits from a healthy aftermarket thanks to gasoline-powered pickups and can be outfitted with parts and pieces to handle more than 1,000 rwhp – even with the torque of a diesel. If your pockets are deep enough, it’s possible to build a 4L80E transmission using aftermarket parts exclusively. For those who just want something that can handle the power of a hopped-up 6.2L or 6.5L engine (about 200 to 300 hp), a stock rebuild with a shift kit and a performance torque converter is just fine.
    Last edited: Jul 3, 2017
  9. Grumpy

    Grumpy The Grumpy Grease Monkey mechanical engineer. Staff Member

    Last edited: Apr 11, 2017
  10. Grumpy

    Grumpy The Grumpy Grease Monkey mechanical engineer. Staff Member


    GM 4L80E Transmission Torque Specs

    Solenoid to Valve Body Screw 8 - 71
    Control Valve Assembly to Case Screw 11 - 97
    Oil Test Hole Plug 11 - 97
    Fly Wheel Housing Cover to Transmission Screw 7 - 62
    Pump body to Cover Screw 24 18 -
    Pump Assembly to Case Screw 24 18 -
    Rear Servo Cover to Case Screw 24 18 -
    Pressure control Solenoid Bracker to Valve Body 8 - 71
    Parking Pawl Bracker to Case Screw 24 18 -
    Accumulator Housing to Valve Body Screw 11 - 97
    Fourth Clutch Screw 16 12 -
    Pan to case Screw 24 18 -
    Extension Housing to Case Screw 34 25 -
    Manual Shaft to Detent Lever Nut 24 18 -
    Speed Sensor to Case Screw 11 - 97
    Case Center Support Screw 39 29 -
    FlyWheel to Converter Screw 44 32 -
    Transmission Case to Engine Screw 44 32 -
    Cooler Pipe Connector Nut @ Case & Radiator 38 28 -
    Valve Body to Case Lube Pipe 11 - 97
    Engine Rear Mount to Transmission Bolt 44 32 -
    Engine Rear Support Bracket to Frame Nut 44 32 -
    Valve Body to Case PSM 11 - 97
    Oil Pan Drain Plug 34 25 -
    Last edited: Aug 20, 2018
  11. stepside

    stepside Well-Known Member

    Strictly Attitude likes this.
  12. Grumpy

    Grumpy The Grumpy Grease Monkey mechanical engineer. Staff Member

    thank you :D
    for posting the additional useful info links
    I'm trying to collect as much related info and useful tips ,
    on the process and suggestions
    as I can in this thread
    Here is a list that I found posted for the trucks that use the 4L80E forChevy.

    AVALANCHE 02-03 4 SP RWD/4X4 V8 8.1L 4L80E

    C/K PICK-UP 1500-2500 95-99 4 SP RWD/4X4 V8 5.0L/5.7L/6.0L/7.4L/6.5L DIESEL4L80E 17 BOLT PAN

    C/K PICK-UP 1500 00-03 4 SP RWD/4X4 V8 6.0L 4L80E

    C/K PICK-UP 2500 00-03 4 SP RWD/4X4 V8 5.7L/6.0L/7.4L/8.1L/6.5 DIESEL4L80E

    C/K PICK-UP 3500 95-03 4 SP RWD/4X4 V8 5.0L/5.7L/6.0L/7.4L/8.1L/6.5L DIESEL4L80E 17 BOLTPAN

    SUBURBAN 1500-2500 95 4 SP RWD/4X4 V8 7.4L/6.5L DIESEL4L80E

    SUBURBAN 1500 96-99 4 SP RWD/4X4 V8 6.5L DIESEL4L80E

    SUBURBAN 2500 96-03 4 SP RWD/4X4 V8 5.7L/6.0L/7.4L/8.1L/6.5L DIESEL4L80E

    TAHOE/YUKON 95-03 4 SP RWD/4X4 V8 6.0L/8.1L/6.5L DIESEL4L80E

    VAN FULL SIZE 2500 96-03 4 SP RWD V6 4.3L V8 4.8L/5.7L/6.0L/8.1L 6.5L DIESEL4L80E 17 BOLT PAN

    VAN FULL SIZE 3500 95-03 4 SP RWD V6 4.3L V8 4.8L/5.7L/6.0L/7.4L/8.1L/6.5L DIESEL4L80E17 BOLT PAN
    Last edited: Feb 13, 2018
  13. stepside

    stepside Well-Known Member

  14. Grumpy

    Grumpy The Grumpy Grease Monkey mechanical engineer. Staff Member

    thank you!!

    tools needed to rebuild a 4l80e transmission listed in the manual


    just a bit of info, if you want a new transmission,core for spare parts,
    I called the local "U-PULL-AUTO-PARTS"
    and the salvage yard quoted me $220
    and I asked again, any auto trans regardless of make/model/year?
    and was told yes..
    but that trans does not come with a warantee its looked at as a core
    so Id be looking for a car/truck, source ,that had been in an accident as it had to be running to be driving,
    if the car/truck you pull it out of,
    is undamaged it MIGHT be in the salvage yard,
    because the trans failed.
    Id also look to see if theres indications,
    the car/truck had been under water or in a fire,
    that might have damaged the transmission

    j-8763-B case holder tool
    j-38655-Holding fixture adapter used with j-8763-B
    j-8001-dial indictor set
    j-25025-B Dial indictor stand & guide pin set caps
    j-38789 -pump removal tool
    j-38358-A -forward clutch housing tool
    j-38868-A -output shaft assembley remover & installer
    j-21363 -lip seal protector
    j-35138- universal converter end play checker
    j-38729 -over run piston seal protetor
    j-21368 -alignment band
    j-38693 -oil pump seal installer
    j-21370-10 -gauge pin
    j-26700-13 -dial indicator base magnet
    j-23327 clutch spring compressor
    j-25018-A -A/T clutch spring compressor adapter
    j-21362 -lip seal protector
    j-21409 -lip seal protector
    j-23093 -center support alignmet tool
    j-38731 -piston seal protector set 3 pieces
    j-38732 -forward clutch seal protectors
    j-38733-A -direct clutch assembly remover & installer
    j-38735 -center support seal installer/sizer
    j-38736 -Six piece turbine shaft seal installer/sizer set
    j-38737 -band apply pin checking tool. Used with J-21370-10
    j-38739 -pump seal installer/sizer

    Last edited: Jul 8, 2018
  15. Maniacmechanic1

    Maniacmechanic1 solid fixture here in the forum

    I got some leads on Torque converters for 4L80E transmissions for High Hp Boost Drag Racing Grumpy.
    A list more than what we had in the past.
    I have to go through and read.
    From the Guys on Facebook Transmission Group.
    Put up a post and they answered.
    1000 -2000 Hp range Hi Boost.
    It will be likely expensive yet.
    But so is Corvette Drag Racing.
  16. JohnHancock

    JohnHancock Well-Known Member

    I watched the guy with the light switches screwed to the dash and I’m not sure I could remember what to flip next! I think I would try micro switches on the shifter. Then it’s like the manual trans with no clutch.
  17. JohnHancock

    JohnHancock Well-Known Member

    stepside likes this.
  18. Grumpy

    Grumpy The Grumpy Grease Monkey mechanical engineer. Staff Member

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