Speeder wrote:

UPDATE:

The new gearset is in. These gears will give me a 2.75 first gear ratio and a 1.57 second gear ratio instead of the factory 2.48 first and 1.48 second. Too bad there's no option for a 0.67 overdrive. Maybe the next rebuild.





I did order, part number 277501.

I'm confused, What they sent you is only 1 planetary gear set, the pictures and description says there is one for the rear and one for the front planetary gear set. Was there something else they sent you in the box? Was the price you paid 973 ish as well? I am seriously considering doing this swap, but was curious about this.
Thanks,
Robby

edit:
SUMMIT RACING has the same exact part # for $200 bux cheaper @ $761.95...... go figure huh?

What you see is what I got. I have no idea if everything is correct, to me a transmission is a magic box that converts torque and RPM. The builder hasn't commented though, so I assume everything is there. I'm also assuming the small gear is the only part that needs to be changed on 2nd gear since there's only a 0.10 difference in the ratio.

UPDATE - Apparently there was a machining issue with the TCI gears, so they are being sent back to TCI for correction. The gears are 20 thousands too large. FLT is in touch with TCI on the issue, and TCI sounds like they are going to fix the issue, but it'll add 2 weeks to the process. Worse comes to worse I'll just go with the 2.48 gears, but I want to avoid that if at all possible. The transfer case is complete though, and it's looking like the total cost is going to be around 3400 bucks. I won't know the total cost until the transmission is sitting at the house though.

was wondering how you were coming with that. looks like it will be sweet. Seems like
tci should give you the more expensive gears you wanted for your trouble. I know how you feel I am waiting to get my front axle back so I can put my truck back on the road

I'm not too worried about it. Told the guy at the trans shop that the delay wasn't important, getting it right was.

Speeder wrote:

UPDATE - Apparently there was a machining issue with the TCI gears, so they are being sent back to TCI for correction. The gears are 20 thousands too large. FLT is in touch with TCI on the issue, and TCI sounds like they are going to fix the issue, but it'll add 2 weeks to the process. Worse comes to worse I'll just go with the 2.48 gears, but I want to avoid that if at all possible. The transfer case is complete though, and it's looking like the total cost is going to be around 3400 bucks. I won't know the total cost until the transmission is sitting at the house though.

Is there anyway to find out how or where these are .020 too big and at what measurement this showed up? Was it that the endplay was too tight?
I am wondering b/c I want to do this swap myself with the help of the ATSG book and if the gears are too big on a measurement that isn't listed in that book or a normal check then I am not experienced enough to check it or know that there is an issue.
I have had 1 80e apart and put it back together and it was simple enough to me doing each sub assembly at a time. I was trying to prevent having the truck down for a looong time "IF" they for some reason haven't gotten the gears built right yet.

any info is greatly useful to me!
Thanks man
Robby

The builder Vince advised that when he had the gears where they go, there was not enough room to get some lock ring in place. They could make it work but couldn't guarantee that the gears wouldn't eat the trans within a few miles. The gears are enroute to TCI now and the turnaround is expected to take 2 weeks from my post. I'll post up what's found when the time comes.

Thanks man, That make sense about the clearance now.

Update - TCI can't seem to get the piece machined right. FLT had to send the unit back for a second time, spoke to them today and they said that the package they had come in turned out to be an input shaft for a powerglide. They are supposed to go back and forth with them today. They said that once they get the part in it'll take them a day to finish and ship, but until it's right... I told FLT that if they were confident in their ability to do so that they can machine the part to make it work, and I'd take responsibility for it not being returnable if they do, but this will be a last stab attempt at it. TCI is the holdup here.

If I wind up having to go with a stock 1-2 gearset, which will happen if TCI can't get it right and FLT does the machining and makes a mistake, I'm going to have to either go back to 3.73s or boost engine power. It's doggy enough on takeoff as it is with the 3.01 from the 4L60E with the tire size and rear gears. It's worth it though, because it'll go 80MPH all day and all night.

The main problem: the gearset is .050 too thick where it goes on the shaft, meaning a thrust washer can't go into place. And, FLT made sure it was the gear and not the shaft, a stock gearset fits perfectly with perfect clearances. We'll see how much longer it takes.

This is how TCI gets you to buy their transmission...........

The inexperienced would jam the thrust washer on, or leave it off and 1,000 miles later it goes Poof!

Kudos to FLT for recognizing the problem and trying to make it right.... Other places would walk away because it is a "customer provided" part.

Speeder wrote:

Update - TCI can't seem to get the piece machined right. FLT had to send the unit back for a second time, spoke to them today and they said that the package they had come in turned out to be an input shaft for a powerglide. They are supposed to go back and forth with them today. They said that once they get the part in it'll take them a day to finish and ship, but until it's right... I told FLT that if they were confident in their ability to do so that they can machine the part to make it work, and I'd take responsibility for it not being returnable if they do, but this will be a last stab attempt at it. TCI is the holdup here.

If I wind up having to go with a stock 1-2 gearset, which will happen if TCI can't get it right and FLT does the machining and makes a mistake, I'm going to have to either go back to 3.73s or boost engine power. It's doggy enough on takeoff as it is with the 3.01 from the 4L60E with the tire size and rear gears. It's worth it though, because it'll go 80MPH all day and all night.

The main problem: the gearset is .050 too thick where it goes on the shaft, meaning a thrust washer can't go into place. And, FLT made sure it was the gear and not the shaft, a stock gearset fits perfectly with perfect clearances. We'll see how much longer it takes.

this is copied from ATSG 4l80e book:
in 1999 and up the center support bearing surface had a 41 thousanths recess cut into it and there was a 41 thousanths shim added between the thrust bearing and the rear internal ring gear to re-center the sun gear in the "revised" planetary pinion gears due to them being 10% thicker than previous models. The sun gear shaft also required 41 thousanths to be machined off of the bottom or the rear bushing journal to accommodate re-centering of the sun gear in the revised planetary pinion gears.

I am glad they are trying to make it right for you especially since it is an aftermarket gear set.
keep up posted!

UPDATE: Apparently TCI finally got their act together. FLT advises that the corrected low gearset arrived and fits perfectly. The trans is together and is ready to ship. They also have a conversion harness ready for me, and will be picking up a Vigilante torque converter correctly sized to put a Gen 1 style trans behind a 5.3L engine. The trans is supposed to have all the updates, and be able to handle the intended HP and torque the truck will be getting in the end. I asked them to ship it out so it'll arrive next week during my days off. I'm really sick of that stupid 4LPOS60e crapmission.

I am very excited for you! I am glad it all came together for sure.. you will surely love the consistent and smooth shifting vs that bang, jerk inconsisitent shitty shifting you have now... I drove my dads 03 z71 a few days ago and forgot sloppy those things really do shift... almost pathetic.
What stall speed did you go with, 2500- 2800?

I went with a stock stall. The main use of this vehicle will be a daily driver for a chick. It'll see highway driving, boat towing, and almost no track time. I only plan to take it to the track to see what it'll do. After I get the transmission dealt with I'll start researching an engine, and I'm leaning towards a 6.0 or a 6.2 for it, and will be aiming at 400-500HP. I want to see how the truck does with the new trans gears before I make that decision. Yes, mileage is still important but not quite so important as it used to be. Besides, I'm pretty sure that by the time I'm done with it it'll still pull down better MPGs than it does now.