Well, I tore the 80e apart today to install all the new transgo goodies, the 4L80e-HD2 kit and the 48MOD vacuum shift pressure regulater kit. While inside the transmission I found that it had been rebuilt before. So much for the 80e's being bullet proof. Again, this unit is a 2002 model. One thing that has me concerned is the fact that the Transgo instructions show to leave the check ball out in the valve body's reverse gear fluid circuit, using 7 check balls instead of 8. I drilled the throttle body spacer plate out to .120" hole diameters in the 1-2-3 clutch circuits, installed the purple spring in the torque converter pressure relief spring, followed all the instructions to make this thing shift HARD! I set the 48mod kit to shift hard, using the stock length pin in the modulator, 1.405" long I believe it was. That's supposed to be almost like putting it into a manual shift pattern. Tearing the trans apart to install the HD intermediate snap ring and direct clutch springs was a bit much but should be well worth the effort. I had to build a few tools to get things apart, like pulling the trans pump and compressing the direct clutch spring pack. Drilling the valve body for the Transgo kit was a bit nerve racking and some of the hole sizes they specified were special number size bits that not many places carry but I happen to have from past projects. Precision Industries had instructions online on how to prepare the 80e pump, also. All this stuff took about 8 hours today, with the trans out of the truck. I guess it would take about 4 hours to do the kit in the truck, not installing the larger snap ring and direct clutch springs.
Something else I noticed in the transmission was plastic accumulater pistons. I should have bought aluminum pistons but I haven't heard of these plastic ones breaking like in the 60e's.
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