80e Install Pics - Need Help

[Quickstop [UK]]

Re: 80e Install Pics - Need Help

Nice work and GREAT pics. I'm hoping to do that to mine in a couple of weeks.

Can you do it yourself or did you need help? I have a trans jack and hi lift axle stands (what REAL Ty owner doesn't? )

 

[mrweelr]

Re: 80e Install Pics - Need Help

Nice work and GREAT pics. I'm hoping to do that to mine in a couple of weeks.

Can you do it yourself or did you need help? I have a trans jack and hi lift axle stands (what REAL Ty owner doesn't? )

My buddy I and lifted the trans and t-case together as one piece onto a Napa 3-ton jack and then carefully slid it into place. Getting it mated to the engine was not simple, though. I had to loosen the motor mounts to get the tranny to slide onto the dowel pins. This is NOT something you want to try by yourself...no way, no how. I swapped the old 700R4 by myself a few times, but not the 80e with the t-case hanging off the back.

 

[MRKING]

Re: 80e Install Pics - Need Help

With the back x-member removed , why didnt you do the trans and case separate ?

As someone who does his all by himself , I also would recommend having a friend help you . Although the trans plate that fits the 2-3 ton jacks makes for an easier time . That , and the jack doesnt drink up all your beer while your working

 

[mrweelr]

Re: 80e Install Pics - Need Help

I didn't use a trans-jack. Just a regular Napa professional series 3-ton jack with the rubber pad under the pan. Yes, it was damn heavy lifting the entire assembly up there as one, but with the crossmember gone it wasn't too bad. Got some more work done today. Propshaft is in, harness wiring is up out of the way, shift-linkage is installed/adjusted, and the bracket for the brace is installed correctly now. Getting real close to having a running Sy again

 

[Mtn Z]

Re: 80e Install Pics - Need Help

Very nice! Looks like you're making some great progress! :tup:

 

[George Blake]

Re: 80e Install Pics - Need Help

That should've been a magazine writeup. That is an incredibly clean truck. I was just looking at it again and can't believe it. It looks like new underneath.

 

[Quickstop [UK]]

Re: 80e Install Pics - Need Help

My transfer case came off with the 700R4 so I guess I could do it separately. I also don't have the torsion bar setup to deal with as the coilovers are in there now.

I can't wait to have a crack at this. You've made it look easy

 

[mrweelr]

Re: 80e Install Pics - Need Help

Thanks for the comments guys. I got some more stuff done today: cut and rerouted the return line from the Derale cooler under the bed, got all the wiring/hoses tied off, relocated the mini-extinguisher, and put the interior back together. At this point, all I need is the chromoly crossmember from RPM and a carbon fiber 80e driveshaft to finish it up. Then it's back to tuning with Nolan. I'm going to just drive it back and forth to work for a while and give everything time to break-in properly. I'm really in no hurry to beat on it. BTW, the truck is filthy...probably the dirtiest it's ever been, but it will get a major detail soon.

 

[TYHOGG]

Re: 80e Install Pics - Need Help

Whats the large gauge red cable goin to the t-case for?

 

[mrweelr]

Re: 80e Install Pics - Need Help

That's just an extra ground cable.

 

[Quickstop [UK]]

Re: 80e Install Pics - Need Help

sorry for the thread hijack but I'm having diffculties with mine..

My trans case adapter plate is pretty tight - the hex bolts won't all go in the same amount and I am terrified of stripping out the thread.

What do you think? Will it be ok? They are below the surface of the plate so the transfer case adaptor will hook up ok but I am just concerned as I thought they would sit more tightly.

The inner race is now very compressed I would imagine. I have only mocked it up for now.

See the left centre bolt is all the way in but the right side isn't?

There doesn't appear to be a gap so I am guessing it is ok....

I also messaged George in his vendor forum.

Thanks.

Merry Christmas!

 

[sparkwire]

Re: 80e Install Pics - Need Help

you may have some debre in the bolt hole, clean out the threads, if these are the bolts supplied with the adapter, they should fit properly and be torqued to specs 25ft lbs

 

[Quickstop [UK]]

Re: 80e Install Pics - Need Help

There was no debris as I test fit the bolts before trying the plate. I thought it was off at first but it was the orientation of the plate. Without the plate the bolts went right in.

There is a very slight misalignment - I'll torque them all up to 25 ftlbs and see where I'm at. Got the trans case aligned and that fit perfectly.

I had a horrible moment where I thought I may not actually have a 4L80E!!

 

[jpalmer]

Re: 80e Install Pics - Need Help

I think sparkwire means maybe something all the way at the end of the hole, get an airgun with a small tube attatched and blow it out all the way inside. maybe inspect with your eye all the way inside to see if maybe there is debris.

Btw George will be the ultimate knowledge on this, when he chimes in.

 

[1BADV6]

Re: 80e Install Pics - Need Help

My JS adapter didn't fit either, some of the holes were out of location compared to the trans. It can be made to work by increasing the size of both the holes and counterbores in the adapter plate. Did your socket head bolts come with the the OD machined smaller? If not, you may need to do that as well.

thanks,

 

[Quickstop [UK]]

Re: 80e Install Pics - Need Help

My JS adapter didn't fit either, some of the holes were out of location compared to the trans. It can be made to work by increasing the size of both the holes and counterbores in the adapter plate. Did your socket head bolts come with the the OD machined smaller? If not, you may need to do that as well.

thanks,

This is the problem. I took a pic and the bolt hoes are not all machined to the same depth so one may be deeper than the one next to it whichis very confusing and a little irritating - I thought CNC would eliminate this error.

Also, the alignment is out and as per your suggestion I am grinding away with my Dremel.

When I took it off, because of the alignment issue there was a very thin line of flashing? that was made when I pressed the adaptor plate in. It should be ok though.

I'm just going to widen the holes and install as per Georges's instructions.

Just to be sure I took the plate off and installed all the bolts and they were all in the same depth sothe plate is the minor problem.

Without these challenges no doubt I'd get bored! Thanks for the input! Keep an eye on my project thread (sig) for my next problem!

Thanks!

Mark

 

[George Blake]

Re: 80e Install Pics - Need Help

Your fine. I've had to dremel MANY of Jeff's plates to get them to fit. Some fit great, some not so great, some not at all. (some holes were off almost 3/8"). CNC is still limited by the ability and age of the equipment. You have one of Jeff's plates. I used a progressive tool and die manufacturer up in Dayton for a while, all perfect. Mike Lee is doing the plates now and they have all aligned perfectly so far. I think it was the ability of the equipment to take the job from start to finish and the age of the equipment. Jeff did what he could but was limited by the equipment he had available. Remember, he was making them in his garage, not a huge tool and die manufacturing facility. The holes are not all the same depth intentionally. Make sure you black RTV it. Don't be paranoid over the bolt depth. I would massage the holes with a dremel if it needs it. You probably have 2 possibly 3 holes slightly off with that plate. It shouldn't be much though.
Also make sure that with the syty aluminum adaptor in place, that the output shaft only sticks out 5/8" or less past the sealing surface. If it sticks out too far, just cut it off with a cutoff wheel. It'll go right through it. This is standard in advanced adaptor's instructions on all of their retrofit kits so don't be upset about that one either. They all specifically state not to smash the transfer case on with the bolts. This is what I try to explain to guys. Some guys run into stuff like this and fix the minor stuff and go on, others won't and kinda get walked through it. That's ok, it's just that it's a cake walk for some and not for others. This is the hardest thing to get people to realize. The ease of this type of project all depends on ability. For example, Jeremy Donavich's components were all CNC'd in Dayton by the PT&D manufacturer so the "made in the garage" factor is gone, but even with the instructions, he still flipped stuff over. It happens. Just take your time, you'll get it in. I highly recommend one of Mike Lee's rear crossmember kits if you've done the coil over. MUCH safer putting it in in two pieces rather than smashing it up in there as one.

 

[1BADV6]

Re: 80e Install Pics - Need Help

Hi George,

I ran into the same problem as Quickstop with my kit. All six holes in my 4L80 case are .940" deep and all six c/bores in the JS plate were all the same depth. The bolts just would not line up. I plotted the six hole locations on the the stock tailhousing on a digital coordinate machine and then compared that to the holes in the JS plate. Most were out of position at least .050" and two were off as much as .150". You could not start all 6 bolts at once without them binding up. Two bolts were very noticably off center in the counter bores. The supplied socket head bolts came with the heads machined down on the OD, obviously to compensate for the misalignment but even that wasn't enough to work. I have not seen one of your current adapter plates, but this is what I found with an early kit. I decided to make a new plate with the holes in the proper location and added grooves to both sides for the factory o-rings and that eliminated the need for any RTV. Not simple by any means, but now everything is fine.

thanks,

 

[George Blake]

Re: 80e Install Pics - Need Help

Now you see my frustration No two plates were the same. I could put 3 plates on the same trans and they all fit different.
There are 7 different case variants that I was trying to compensate for. I'm trying to remember, but it seems the LATER cases had all of them the same depth. Some even have one bolt hole that enters a passage with trans fluid, not under pressure but did have fluid in it. It's surprising. I've even found 5 different center support variants and 3 OD crown and matching case variants. Fun trying to make one plate fit them all. The plates that I had made in Dayton and the ones Mike now does have tolerance to take into account core shift. That was the nice thing about using an OEM manufacturer to do the plates. You can get access to those specs:tup: For example, when the plates are done now, it NEVER leaves the machine until it is done. That goes a LONG way in repeatability and accuracy.
The nice thing about that whole experience was that you learn what to expect and learn when to have the confidence in a manufacturer to produce something along the lines of the planetaries that I did. HUGE difference when you have to have something perfect verses, every-one-is-different kinda production.

Hi George,

I ran into the same problem as Quickstop with my kit. All six holes in my 4L80 case are .940" deep and all six c/bores in the JS plate were all the same depth. The bolts just would not line up. I plotted the six hole locations on the the stock tailhousing on a digital coordinate machine and then compared that to the holes in the JS plate. Most were out of position at least .050" and two were off as much as .150". You could not start all 6 bolts at once without them binding up. Two bolts were very noticably off center in the counter bores. The supplied socket head bolts came with the heads machined down on the OD, obviously to compensate for the misalignment but even that wasn't enough to work. I have not seen one of your current adapter plates, but this is what I found with an early kit. I decided to make a new plate with the holes in the proper location and added grooves to both sides for the factory o-rings and that eliminated the need for any RTV. Not simple by any means, but now everything is fine.

thanks,

 

[SY-1193]

Re: 80e Install Pics - Need Help

Quickstop,
Take out the bolt that won't go all the way in and compare it to another bolt closely.
Check that the Thread Pitch / Teeth Per Inch is the same by holding the threads together.
Sometimes bolts get mixed in at the factory.
Just check before you tighten it anymore.
It may be the bolt size is the same but the thread pitch / teeth per inch is off and causing it to bind on the way in.