My 4L60e to 4L80e Swap Journal:

[Erickk120]

Is it dimensional impossible for it to fit, or is the problem just getting over the torsion member to make it fit? If it just wont fit, maybe some cutting will be needed, which should be fine as long as you weld some sort of re enforcing.

 

[srs5150]

It's in.

I'm not saying this is how it should be done, but this is what finally worked for me. I took the transfer case adapter off so I could get the transfer case studs up and far back enough to put the transfer case adapter back on. It wasn't easy, but with a lot of back and forth and back and forth and some wiggling, the transmission output shaft and transfer case input finally lined up.

One thing that saved my arms - I cut a 2x4 the length of the distance from my floor to the bottom of the transfer case (the trans jack was too much in the way). When my arms got too tired of wiggling, I set the 2x4 in place and took a break. Then went back to it. Last night I just man handled it to complete exhaustion (and frustration).

I really hope this helps someone someday.

 

[randeez]

tranfercase is awkward as hell, as it sits clocked uneven so putting a jack or something under it doesnt work. i dont know if the awd is any lighter, prob ~60lbs or so, but the only thing that works for me is just to get it under there and throw it on my chest and manhandle it into place. on the gmt900, the tail needs to go over the crossmember first then lift the front up to the transmission adapter. but there is plenty of room to do it with no torsion bars

 

[Rocket Man]

tranfercase is awkward as hell, as it sits clocked uneven so putting a jack or something under it doesnt work. i dont know if the awd is any lighter, prob ~60lbs or so, but the only thing that works for me is just to get it under there and throw it on my chest and manhandle it into place. on the gmt900, the tail needs to go over the crossmember first then lift the front up to the transmission adapter. but there is plenty of room to do it with no torsion bars

Yessir, that’s how I did mine in my 02 Denali. 60 lbs doesn’t sound like much but in an awkward position like that, it’s a *****. There’s no way to use a trans jack.

 

[HiHoeSilver]

Yessir, that’s how I did mine in my 02 Denali. 60 lbs doesn’t sound like much but in an awkward position like that, it’s a *****. There’s no way to use a trans jack.

Bench it, buddy!

 

[Erickk120]

Glad you made it work, without having to hack anything. Following this as well!

 

[Rocket Man]

Bench it, buddy!

Yessir I did, and my arms still hurt.

 

[srs5150]

.... It's the DETAILS that slow you down!


I was able to get the NSS on easily (which I promptly removed because I needed access to the oil port and front speed sensor).




After removing it, I put on the front speed sensor (from the kit I bought) and my trans oil temp sensor.




And then I hit a hiccup with the bracket that holds the shift control cable when I tried to transfer my 4L60e one to the 4L80e. It's a NO GO. See last picture. I'm holding it below its mounting point for reference, but you get the idea on how much longer it is.




So, I ordered part number 15013290 and will wait 4 days for it to arrive:




All the transfer case connections are made and I'll be going after the trans cooler lines next.........

 

[randeez]

Will the gear selector lever work where it is?
On mine it's right on top of the front driveshaft. I had to take two of them and offset it closer to the pan to make it work. My cable rides along the pan rail to change gears...at the moment it will only go into P R N D and 3 is iffy

 

[srs5150]

The bracket that holds the shift control cable came. Now I realize I don't have the right fasteners for it. Anyone have a clue what to use?