Transmission Questions, Lots of them

[erasedhammer]

I've gone over the TM's and all the forum posts about the 4l80 swaps, and they simply aren't answering my questions.

So first, my vehicle is a m998a1 with the rear caliper parking break and the 242 transfer case along with the 6.2 na, 3 speed. I know that this changes some things so I'd like some input about what parts of the process I can skip due to some of the already installed upgrades.

I got this list of parts from another post:
I am not very good at google fu'ing things, so please do provide links if possible and be patience with me.

[FONT=&quot]Parts List[/FONT]
[FONT=&quot]----------------------------------------------[/FONT]
[FONT=&quot]Transmission Parts[/FONT]
[FONT=&quot]-----------------------[/FONT]
[FONT=&quot]4L80-E Transmission [/FONT]
[FONT=&quot]4L80-E Crossmember[/FONT]
[FONT=&quot]Transmission Mount (Old one can be re-used, but don't) - Hummerpartsguy[/FONT]
[FONT=&quot]Transmission Shift Linkage[/FONT]
[FONT=&quot]Dipstick Tube - Hummerpartsguy[/FONT]
[FONT=&quot]Dipstick Tube Seal - Hummerpartsguy[/FONT]
[FONT=&quot]Dipstick - Hummerpartsguy[/FONT]
[FONT=&quot]4-Speed Shifter[/FONT]

[FONT=&quot]Transfer Case Parts[/FONT]
[FONT=&quot]-----------------------[/FONT]
[FONT=&quot]Transmission to Transfer Case Adapter - dont need because I already have the 242?[/FONT]
[FONT=&quot]Transfer Case Adapter Drain Plug - Hummerpartsguy[/FONT]
[FONT=&quot]Transfer Case Shift Linkage - Never seen one anywhere[/FONT]

[FONT=&quot]Drive line[/FONT]
[FONT=&quot]-----------------------[/FONT]
[FONT=&quot]A2 Front Drive Shaft (Only the section between the slip joint and the T-Case) (Alternatively, lengthen the existing shaft by 2? inches) Heard I don't need this? Cause I already have the 242?[/FONT]
[FONT=&quot]A2 Rear Drive Shaft (Shortened 7/8" if you plan to keep the drive shaft parking brake)m> Don't see them on the auction site, where to get them?[/FONT]

[FONT=&quot]Electrical - I have the 200 amp dual voltage alternator [/FONT]
[FONT=&quot]-----------------------[/FONT]
[FONT=&quot]Transmission Computer[/FONT]
[FONT=&quot]Transmission Warning Lamp - Kascar[/FONT]
[FONT=&quot]Transfer Case Lock Lamp - Hummerpartsguy[/FONT]
[FONT=&quot]Double Brake Switch[/FONT]
[FONT=&quot]Double Brake Switch Linkage - Hummerpartsguy[/FONT]
[FONT=&quot]Engine Speed Sensor- I would use the crank sensor correct?[/FONT]
[FONT=&quot]Throttle Position Sensor - AIRTEX / WELLS Part # 5S5080 (TPS146) or BWD EC3003[/FONT]
[FONT=&quot]Fan Cutout Switch Bracket - Kascar[/FONT]
[FONT=&quot]Fan Cutout Switch Linkage[/FONT]

[FONT=&quot]If you plan to build a harness:[/FONT]

[FONT=&quot]16ga Prestolite Wire - Erik's Military Surplus[/FONT]
[FONT=&quot]Harness Stub with TCM Connector - Get this cut out of a scrapped truck[/FONT]
[FONT=&quot]Transmission Connector - ebay[/FONT]
[FONT=&quot]Transmission Speed Sensor Connector (x2) - ebay[/FONT]
[FONT=&quot]Rubber Bullet Connectors (Male and Female) - Erik's Military Surplus[/FONT]
[FONT=&quot]Rubber Y Connectors (Female) - Erik's Military Surplus[/FONT]
[FONT=&quot]Headlight Bulkhead Connectors (Male) - Erik's Military Surplus[/FONT]
[FONT=&quot]2-Pin Sureseal Connectors (Receptacle) - [/FONT]http://www.newark.com[FONT=&quot] P/N 120-1804-000[/FONT]
[FONT=&quot]Sureseal Connector Crimp Pins - [/FONT]http://www.newark.com[FONT=&quot] P/N's 030-2196-001 and 031-1267-001[/FONT]
[FONT=&quot]16ga Ring Termals for Battery Connections[/FONT]

[FONT=Lucida Grande, Trebuchet MS, Verdana, Helvetica, Arial, sans-serif]Otherwise buy an A2 body harness - [/FONT][FONT=Lucida Grande, Trebuchet MS, Verdana, Helvetica, Arial, sans-serif]Where to get this?[/FONT]
[FONT=Lucida Grande, Trebuchet MS, Verdana, Helvetica, Arial, sans-serif]Alternatively, I heard you can use an h1's harness with a 6.2 na and 4l80, anyone know where to get this, maybe hummerpartsguy? Do the harness's work with the military tcm?[/FONT]

[FONT=Lucida Grande, Trebuchet MS, Verdana, Helvetica, Arial, sans-serif]Any other modifications necessary that aren't mentioned here? [/FONT]

 

[NDT]

Recall that the 4L80E is 2" longer than the TH400, so driveshaft modifications or replacement is inevitable. Has someone published how to manufacture a stand alone harness from the 4L80E to the military controller?

 

[86humv]

So...your planning on using the 6.2 ?

 

[erasedhammer]

So...your planning on using the 6.2 ?

Yes, Don't have the money for both the transmission and a 6.5l.

 

[ari]

I am trying to do the same i have the same drive line as you but with a 6.5 i am fairly sure the 4l80e will bolt right in with the T Case adapter plate and cross member without shortening the driveshaft since its already got the 242. I sourced ever single part you have listed and the price is quite hefty especially the wire harness PN 12460097 . I think I will go with a aftermarket controller www.usshift.com/usq4.shtml seems very straight forward for installation but i will put the TCM in a clear water proof box though.

 

[86humv]

All trucks with a 3l80 and a 242 T/C, still need a different X member, T/C adapter, and drive shafts at a minimum.

 

[ari]

I'm aware of the new X member and adapter plate. But as for the drive shaft is there a Part number for it?

 

[erasedhammer]

I am trying to do the same i have the same drive line as you but with a 6.5 i am fairly sure the 4l80e will bolt right in with the T Case adapter plate and cross member without shortening the driveshaft since its already got the 242. I sourced ever single part you have listed and the price is quite hefty especially the wire harness PN 12460097. I think I will go with a aftermarket controller www.usshift.com/usq4.shtml seems very straight forward for installation but i will put the TCM in a clear water proof box though.

I already have the military TCM on order, got it for about 300. Does that part number you reference include all the wiring needed for the 4l80 swap?

 

[ari]

to the best of my knowledge it does it does include everything needed and alot thats not needed.

 

[BLK HMMWV]

I am trying to do the same i have the same drive line as you but with a 6.5 i am fairly sure the 4l80e will bolt right in with the T Case adapter plate and cross member without shortening the driveshaft since its already got the 242. I sourced ever single part you have listed and the price is quite hefty especially the wire harness PN 12460097. I think I will go with a aftermarket controller www.usshift.com/usq4.shtml seems very straight forward for installation but i will put the TCM in a clear water proof box though.

Did you ever look at the TCI EZ-TCU for an aftermarket TCU just curious why you like the US Shift one?

 

[ari]

Did you ever look at the TCI EZ-TCU for an aftermarket TCU just curious why you like the US Shift one?

I looked at both I have never used either one so I have no opinion. Is the TCI EZ-TCU better?

 

[86humv]

I already have the military TCM on order, got it for about 300. Does that part number you reference include all the wiring needed for the 4l80 swap?

You don't need the TCM if you go after market trans controller.

 

[erasedhammer]

You don't need the TCM if you go after market trans controller.

Well it's an either or, right? Either I use the military tcm or a civilian one. I much rather use the military one, keeping the truck closer to the military side of things.

 

[erasedhammer]

All trucks with a 3l80 and a 242 T/C, still need a different X member, T/C adapter, and drive shafts at a minimum.

Wasn't the 242 tc made for the 4l80 and thus to have the 242 on the 3l80 require an adapter? If so that would mean that there is already an adapter on there on mine and all I would need to do to connect it to the 4l80 is to remove that adapter plate?

 

[Action]

it isn't really a plate. it is several inches thick. there are different ones available. they slide over studs on the trans and studs on the t/c.

here is an example....
https://www.real4wd.com/zedSuite/assets/catalog/parts/12339134U.jpg

 

[86humv]

Wasn't the 242 tc made for the 4l80 and thus to have the 242 on the 3l80 require an adapter? If so that would mean that there is already an adapter on there on mine and all I would need to do to connect it to the 4l80 is to remove that adapter plate?

There are two different T/C 242's that can fit on a 3l80....both use the same adapter as the T/C 218.
The 4l80E trans uses a different adapter....I have them ...new.

 

[erasedhammer]

There are two different T/C 242's that can fit on a 3l80....both use the same adapter as the T/C 218.
The 4l80E trans uses a different adapter....I have them ...new.

Could I buy one of them off of you? How much, and are you selling on the auction site?

 

[86humv]

Could I buy one of them off of you? How much, and are you selling on the auction site?

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