Questions on 4L60E to 4L80E swap.

[ResourceReaper]

So in reality, I'm looking at 80E trans, transfer case, harness, yoke, and drive shaft modification? Correct me if I am wrong, but if I have a 05 Silverado Ext Cab, I should be able to use a drive shaft from:

AVALANCHE 1500 02-06 4x4
ESCALADE ESV 03-06
ESCALADE EXT 03-06
SUBURBAN 1500 00-06 4x4
YUKON XL 1500 00 4x4
YUKON XL 1500 01-02 4x4; exc. Denali
YUKON XL 1500 03-06 4x4

[kewljay223]

if they are all 1500's wouldnt they have the 60e? which would give you the same shaft you have now right??? or do you mean the 2500/3500 versions of what you listed?? if thats the case and you go that route, Mickey warned me about the possibility of the rear end being different (HD truck) which means that u-joint might not fit....

to be honest, you might save some money going that route but you might have to change the joint and who knows if the shaft is bent/ or whatever. im at the end of my 80e swap right now. i went with just modding mine. i didnt want the headace of searching around for a shaft and getting it checked out anyway. the shop called me today as a matter of fact saying that its done. ill be picking it up tomorrow and putting it in. everything else is done. theoretically i should be able to drive it by end of day.....

unfortunately it will cost me about 500 bucks because they are replacing all joints, carrier bearing, new yoke, shortening it and balancing . i didnt have to do all that but the shaft/parts are 18yrs old.... haha time for sevice. if you just get it shortened its about 120 bucks + cost of yoke. since yours is an 05 thats all you should have to do.

for the flex plate, kinda depends what converter your gonna use. is a stock one coming with your trans? if not you obviously gotta buy one. if you get a stock one yes, you will need FLAT flex plate and spacer. if you get aftermarket with stall (what i did from site sponsor circle D) they have an 80e verter with a 60e bolt pattern which is what i got. this allows you to use your stock dished plate WITHOUT spacer. you just need to oblong the 3 holes a bit. thats pretty much your only 2 options AFAIK.

if you dont mind doing the wiring, you dont need to spend 100 bucks on the harness adapter. just take apart the round conector and move two pins around. the only other wiring is adding the two wires for the fron VSS and pinning them into the PCM connectors. 4 wires TOTAL to deal with. DONE. read a few pages into this thread and it shows you exactly how. pretty easy to do. http://www.performancetrucks.net/for...-4l80e-424904/

and i think you said you have the rest covered such as oil cooler lines and crossmember mod. good luck!

oh and there are 3-4 different output shafts on the 80e's you will have to look at yours to get the correct yoke. i was able to look in through the seal with a flashlight and see that i had the kind with the splines that went the full 5" some only go about 3 and have an oring. some are slip yokes only. some are bolt on. just make sure you get the right one. you might have to take the rear housing off to know for sure... bu i cant help you much more than that though.

[ResourceReaper]

kewljay, I cannot thank you and everyone else here enough. It almost is looking like this is something that I cannot do in a weekend. So here is where I am.

They did make a (get this) 2005 Silverado 1500HD which had the 6.0L and 4L80E engine. But I'm not finding anything on the transfer case that was in there. I'm still researching though.

I found a j/y trans for $750. I figured that I might as well completely replace the transfer case with a new one (it's 225K on the truck... I think it might be time). It never dawned on me to see if they made a manual transfer case for the 2500HD since mine is a manual (floor mounted) shift, which I have to be honest, I prefer. I guess does it matter? If the 80E's transfer case is only electric motor driven, how much work is it to wire up the dash selector switch? I think (hopefully) this is one of the last questions I'm going to have until I start buying stuff. To solve the drive shaft issues, I'm going with a new drive shaft from Denny's. I want to go with a new yoke, front and rear shafts.