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6L80e 6spd Conversion

A

adventr

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500
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United States
Hey guys! Got a message on IG. Lol

Sorry I don't check in here much. I stay pretty busy with the business/projects/life.

Just to clarify, Moser Engineering did cut/respline my output shaft. They've also done at least 1 other that I've personally seen. Depending on who you talk to there, they'll say that their fly cutter will get into the shell/radius.... Just tell them to send it. :giggle:


If you look closely at the pictures of mine (maybe I didn't post close-ups? Can't remember that far back), you'll see where their tooling lightly nicked mine. It's no big deal.

Closeup pics on post# 120. Tell them to get the splines down as far as they can, and that it's ok if they end up grazing the radius'd portion of the shaft. That's not a sealing surface.
 
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RamRod

RamRod

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Messages
3,914
Location
AB, Canada
adventr said:
Hey guys! Got a message on IG. Lol

Sorry I don't check in here much. I stay pretty busy with the business/projects/life.

Just to clarify, Moser Engineering did cut/respline my output shaft. They've also done at least 1 other that I've personally seen. Depending on who you talk to there, they'll say that their fly cutter will get into the shell/radius.... Just tell them to send it. :giggle:


If you look closely at the pictures of mine (maybe I didn't post close-ups? Can't remember that far back), you'll see where their tooling lightly nicked mine. It's no big deal.

Closeup pics on post# 120. Tell them to get the splines down as far as they can, and that it's ok if they end up grazing the radius'd portion of the shaft. That's not a sealing surface.
Click to expand...

Thanks for stopping by!! We miss ya around here!!
 
A

atvspeed4

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Messages
1,211
Location
massachusetts
Well I figured this would be useful info for others so they do not waste the time or money... We finally found a 2008 H2 transfercase 32 spline input shaft and planetary assembly to try and swap into a base H3 transfercase. The 27 spline H3 input/ planetary is on the left and the H2 32 spline planetary is on the right. The H3 is only a 4 pinion assembly an the H2 is a 6 pinion assembly. The H2 6 pinion planetary perfectly fits into the H3 case and has the correct mesh gears but the 32 spline input is WAY to short and does not get close to reaching the seal. Unlike New Process transfercases where you can swap just the input shaft into different planetaries the ones in both H3/H2 are pressed and riveted together.

So long story short is its not possible to swap the input shafts in a stock H3 case. I even looked at trying to find other brand inputs that might have same gear cut but no other transfercase out there has as long as an input as an H3.


Input shafts.jpg
 
A

atvspeed4

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Messages
1,211
Location
massachusetts
06 H3 said:
So basically your stuck with resplining a 32spline output to the 27 spline so it can mate to a BW4493/4
Click to expand...
Yup which is fine for stock HP levels but without reheat treatment I am nervous for high HP builds and snapping the shaft

Sent from my Pixel XL using Tapatalk
 
A

atvspeed4

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Messages
1,211
Location
massachusetts
Another thing to note is I have been working with a couple of companies, including the one that did the harness in this thread, to order what I need. One thing that was left out is I was told that I would lose the ability to select each downshift to 3-2-1as seen on the H3 cluster. They are still working on sorting that part out for our platform.

Sent from my Pixel XL using Tapatalk
 
06 H3

06 H3

a.k.a. "The Jackal"
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Meridian, ID
Interesting, I'm curious if they would do some type of paddle shifter...I think that's what they do on the JK swaps....

I'm curious if the H3 planetary will swap with a BW1356 from Ford...they sell doubler boxes for those and it would be cool to drop in an H3 planetary. I'm looking into an NP205 with a doubler box. Already have the 205...and with the SAS I can finally have a true 2 wheel drive mode. I just don't wanna give up the 4:1. A doubler will solve that.

Sorry for the tangent, good info here
 
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atvspeed4

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1,211
Location
massachusetts
The problem with our dash cluster and paddle shifters is there is no indication of what gear you are in. You would have to put it in the "3" detent but that would actually be "M" and you would have no clue what gear you are in.

I would not be surprised if BW used the same gear cut on all of the T-cases but I would just go dana 300 with 4:1 kit. We have been running the NP241 in ours with 2wd for months now and I kinda miss the AWD. We will be building a dana 300 soon or buying an atlas now that we figured out the electronics. I would not run a doubler as there is barely enough room for us to run our custom shifter tower and one T-case lever in the factory console.
 
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atvspeed4

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massachusetts
Alpha X

Alpha X

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Messages
453
Location
The Motor City
Has anybody else done the 6L80e conversion? Are there any turned down output shafts out there collecting dust that haven't been used?
 
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atvspeed4

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Messages
1,211
Location
massachusetts
Alpha X said:
Has anybody else done the 6L80e conversion? Are there any turned down output shafts out there collecting dust that haven't been used?
Click to expand...
Our turned down output shaft should be here end of next week. We are going to try and get it reheat treated then cryoed but don't have much faith in it after seeing how many guys have twisted cryoed 27 spline 4l60 outputs in trailblazer SS.

Tried finding a shop to build 4340 output but no go due to it's design. Only chance is to find specialist shop to build transfercase 32 spline input but there is different one for base and adventure transfer case on top of the fact we will need to order a large run of them.
 
Korby7

Korby7

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Messages
434
Location
Utah
atvspeed4 said:
Our turned down output shaft should be here end of next week. We are going to try and get it reheat treated then cryoed but don't have much faith in it after seeing how many guys have twisted cryoed 27 spline 4l60 outputs in trailblazer SS.

Tried finding a shop to build 4340 output but no go due to it's design. Only chance is to find specialist shop to build transfercase 32 spline input but there is different one for base and adventure transfer case on top of the fact we will need to order a large run of them.
Click to expand...

How large of a run? I’d be interested in one, maybe 2 depending on price.
 
Alpha X

Alpha X

Well-Known Member
Messages
453
Location
The Motor City
atvspeed4 said:
Our turned down output shaft should be here end of next week. We are going to try and get it reheat treated then cryoed but don't have much faith in it after seeing how many guys have twisted cryoed 27 spline 4l60 outputs in trailblazer SS.
Click to expand...

So how does this pertain to the 6L80 turned down output shaft? Is it because the 6L80 turned down 27 spline output shaft has a smaller diameter and isn't as strong at the unmodified 32 spline output shaft?
 
A

atvspeed4

Well-Known Member
Messages
1,211
Location
massachusetts
Alpha X said:
So how does this pertain to the 6L80 turned down output shaft? Is it because the 6L80 turned down 27 spline output shaft has a smaller diameter and isn't as strong at the unmodified 32 spline output shaft?
Click to expand...

A OEM 32 spline is much stronger than an OEM 27 spline shaft in any application. What I was referencing is there are many examples of 27 spline outputs on other platforms twisting the splines or snapping.

When you turn down and respline the stock 32 spline output shaft you are removing a good portion of the induction hardened outer layer. We have not tested how deep the OEM heat treat goes but its usually not much.
 
High Five H2

High Five H2

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1,627
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West Texas
atvspeed4 said:
Well I figured this would be useful info for others so they do not waste the time or money... We finally found a 2008 H2 transfercase 32 spline input shaft and planetary assembly to try and swap into a base H3 transfercase. The 27 spline H3 input/ planetary is on the left and the H2 32 spline planetary is on the right. The H3 is only a 4 pinion assembly an the H2 is a 6 pinion assembly. The H2 6 pinion planetary perfectly fits into the H3 case and has the correct mesh gears but the 32 spline input is WAY to short and does not get close to reaching the seal. Unlike New Process transfercases where you can swap just the input shaft into different planetaries the ones in both H3/H2 are pressed and riveted together.

So long story short is its not possible to swap the input shafts in a stock H3 case. I even looked at trying to find other brand inputs that might have same gear cut but no other transfercase out there has as long as an input as an H3.


View attachment 22629
Click to expand...

What if you swapped the input shafts and used an adapter that was an inch shorter?
 
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