Looking at swapping a 6L80 in place of 4L60. I was told it would be easier to replace the transfer case with one that has a 32 spline to match the 6L80 instead of attempting to adapt the 6L80 to the 27spline of the standard transfer case. Has anyone found a compatible transfer case option?
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Transfer Case that will accept 32 spline of 6L80
- Thread starter 68topls
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I'm running the factory transfer case on a 6L80e. I had the output shaft turned down to the smaller diameter 27 spline. The output shaft is the first thing inserted into the case so everything has to come out to swap it.
If you go this route, my recommendation would be to get another output shaft and send it to get it recut and then take the parts and the bare transmission to a shop and let them swap it for you. It's a 2-3 hour job tops on the bench.
If you go this route, my recommendation would be to get another output shaft and send it to get it recut and then take the parts and the bare transmission to a shop and let them swap it for you. It's a 2-3 hour job tops on the bench.
OK. So purchase a 32 spline output Shafter for the 6L80. Send it out to get recut then take to a shop to swap. Are you running and 5.3 /6.0 swapped in as well? Where there any other modifications required to replace your 4L60?
Would any machine shop be able to recut the output shaft or should I be looking for some place specific?
Happy Hummer
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You could also do a "Monster in the box" on your 4L60e.. I watched a dvd I have where Ian and Jessi swapped the whole shebang.
rascole
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Agree, swapping a 6L80 is a lot of work and money to run a stock motor and suspension. 4L60 can be built to handle more power than those components can handle.
cgalpha08
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Need @06 H3 and @EndeavoredH3 to chime in here as they have dealt with 6 speed swaps.
You can get these transfer cases to work with a 6 speed with no recutting of the output shaft as they are passenger drop
Atlas transfer case
NP205 transfer case
But those require levers or cables to shift them, so the computer wont be happy.
You could also plug the encoder motor in to keep the computer happy and still "shift the t case" with the dash that way the computer is no wiser and you get the better T case. I think @06 H3 does this.
You can get these transfer cases to work with a 6 speed with no recutting of the output shaft as they are passenger drop
Atlas transfer case
NP205 transfer case
But those require levers or cables to shift them, so the computer wont be happy.
You could also plug the encoder motor in to keep the computer happy and still "shift the t case" with the dash that way the computer is no wiser and you get the better T case. I think @06 H3 does this.
Gosh. Yes adapter flange. Sorry but you just reminded me that the output shaft was just one piece of the puzzle. I forgot all of the other work that went into this setup.
Ok first, you need to define what you are looking for. If you want to retain factory functionality, awd, and passenger side drop, the factory case is the route. If you go with another 32 spline case, you will
also have other considerations such as cable shifted? What's out there that's passenger drop? Driveshaft modifications, no awd options.
Ok, behemoth out of Kentucky for the machining. I've got almost 50k on this output shaft with no issues.
Adapter flange. My setup uses the generic Novak 6l80e adapter and then a custom flange to adapt the factory case to that. Novak adapter is 3.25" long and the adapter is 0.75" to give the same 4" takeup as the factory setup. I could not find a suitable off the shelf trans mount so I fabbed my own with a castable urethane and a steel angle for the foot.
I'm more than willing to help you get all of this assembled if you pursue it. For the adapter flange I have the cad and solid model files if you want them. I used xometry to fab them.
Ok first, you need to define what you are looking for. If you want to retain factory functionality, awd, and passenger side drop, the factory case is the route. If you go with another 32 spline case, you will
also have other considerations such as cable shifted? What's out there that's passenger drop? Driveshaft modifications, no awd options.
Ok, behemoth out of Kentucky for the machining. I've got almost 50k on this output shaft with no issues.
Adapter flange. My setup uses the generic Novak 6l80e adapter and then a custom flange to adapt the factory case to that. Novak adapter is 3.25" long and the adapter is 0.75" to give the same 4" takeup as the factory setup. I could not find a suitable off the shelf trans mount so I fabbed my own with a castable urethane and a steel angle for the foot.
I'm more than willing to help you get all of this assembled if you pursue it. For the adapter flange I have the cad and solid model files if you want them. I used xometry to fab them.
I'm obviously far from a stock setup but the 6 speed is a night and day difference from the 4. It was well worth the effort in my case and I think 06h3 doesn't regret his choice either. We are both also running tap shifting which is a nice feature.
If I had less common sense I'd like to find a beater I5 and swap an 8 speed into it.
Also my opinion any v8 swap should not even be considering keeping the 4L60e and going straight to the 6L80e
@CaseyS I would like to retain factory functionality with AWD (4LO) and passenger side drop. I intend to use the engine and trans from an 08 Cadillac Escalade (L92 + 6l80). If you're willing to assist in getting the required items assembled that would be great. I could also fully document it for the next person. So far these are the items I have come up with:
32 spline output shaft machined to 27 spline
Novak 6L80E Adapter Flange
Custom Flange to adapt to factory transfer case
Transmission Cooler
Transmission Cooler Lines
Aftermarket Dip Stick & Tube (flexible)
Shift linkage
Shift cable bracket
Vent Tube
Cabling & Stand Alone Transmission Module (?)
Transmount / Crossmember
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Conversion shift shaft
add this to your list. Let's you keep the factory shift quadrant wiring. I wish this was available when I did mine. I had to use relays for the park and reverse and wire that into my harness.
No mods are necessary for the shift cables. It fits right on 6L80e. I think I have a lokar dipstick that I ended up not using. I'll look for it.
Hit up 06H3 for what's required on the wiring side. He has a similar setup.
For the trans cooler there is a part that adapts the 6l80e cooling ports to 6-an. Search on Amazon or ebay. I then used some generic amazon hose and -an to hook up to the factory cooler. I'm not running an external cooler.
Also since you mentioned the escalade drivetrain I assume this is a v8 conversion and you know the differences of starting with an 06-07 i5 vs an 08-10 i5 vs an alpha upgrade conversion.
add this to your list. Let's you keep the factory shift quadrant wiring. I wish this was available when I did mine. I had to use relays for the park and reverse and wire that into my harness.
No mods are necessary for the shift cables. It fits right on 6L80e. I think I have a lokar dipstick that I ended up not using. I'll look for it.
Hit up 06H3 for what's required on the wiring side. He has a similar setup.
For the trans cooler there is a part that adapts the 6l80e cooling ports to 6-an. Search on Amazon or ebay. I then used some generic amazon hose and -an to hook up to the factory cooler. I'm not running an external cooler.
Also since you mentioned the escalade drivetrain I assume this is a v8 conversion and you know the differences of starting with an 06-07 i5 vs an 08-10 i5 vs an alpha upgrade conversion.
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Is the Novak setup the one they advertise for the jeep?
I got your PM. I'll get you some info over email.
As far as novak, yes it's the same adapter as in the jeep kits. Give them a call, you only need the bare adapter, not all the other stuff in the kit. I think they labeled the part as a 6L81 and I recall it was $395 about 4 years ago.
As far as novak, yes it's the same adapter as in the jeep kits. Give them a call, you only need the bare adapter, not all the other stuff in the kit. I think they labeled the part as a 6L81 and I recall it was $395 about 4 years ago.
2006-2011 GMT365: I5-V8 (H3, H3 Alpha, H3T)
2006-2011 GMT365: I5-V8 (H3, H3 Alpha, H3T) BASIC PACKAGE (I5 Engine) : TBM-SPEC 6L50 (TBM Atlas bellhousing adapter, TBM Transfer Case Adapter, TBM 27 Spline, Pre-programmed TCM, 400 HP, BILLET torque converter, 2400 RPM stall, AN fitting BILLET cooler line block, Transmission dipstick & tube...
truebluemotorsport.com
Alpha X
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I have a 6L80e output shaft that has been resplined to fit our transfer cases. It was purchased from another forum member in 2018, and I don't think I'll be using it. I'll sell it if you're interested. Feel free to message me.
little diesel
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wow this is worth looking into2006-2011 GMT365: I5-V8 (H3, H3 Alpha, H3T)
2006-2011 GMT365: I5-V8 (H3, H3 Alpha, H3T) BASIC PACKAGE (I5 Engine) : TBM-SPEC 6L50 (TBM Atlas bellhousing adapter, TBM Transfer Case Adapter, TBM 27 Spline, Pre-programmed TCM, 400 HP, BILLET torque converter, 2400 RPM stall, AN fitting BILLET cooler line block, Transmission dipstick & tube...
pickledill
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I intend on using the AWD T-case (NP149) out of a escalade along with the 6l80e and L92, however I'm cheap and I miss driving a noisy v8 so I'll probably end up going with a 27 spline output shaft to work with the stock system until the front diff or T-case explodes, then I'll do a driver side diff swap with Corvette coilovers to delete the torsion bars
Not sure how that longer manual shaft works to allow the factory wiring? I am not familiar with transmission stuff at all. I more than likely intend on modifying the gear selector system anyways as I'll be adding paddle shifters for manual mode
I have spoken to the guy over at truebluemotorsport for a 6l80e conversion, he quoted me about $1200, this was for a RWD V8 Colorado however and I have my own transmission. hes quite friendly
Not sure how that longer manual shaft works to allow the factory wiring? I am not familiar with transmission stuff at all. I more than likely intend on modifying the gear selector system anyways as I'll be adding paddle shifters for manual mode
I have spoken to the guy over at truebluemotorsport for a 6l80e conversion, he quoted me about $1200, this was for a RWD V8 Colorado however and I have my own transmission. hes quite friendly