5 speed to a4

[Kevin2177]

Yes I already know it will be cheaper to buy and ls car or roller then doing this. This is just something I wanted to always do and I have the time and space for it. I have a 2001 3.8 with a 5 speed. I know for the engine harness I will just need a 99-02 engine harness and pcm. I will be switching from a manual to a 4l80e. Will a 4l80e harness just plug right in?

[ssms5411]

You'd be better off doing a 4l60e which was a option. Any reason you want to swap trannys?

[LETZRIDE]

The 4L80e is much stronger than the 4L60e. To put a 4L80 transmission in you’ll need to do the following:



~ 97+ 4l80e transmission. The older ones will work but may have to be modified. Ive also read below 97 the 4l80e's werent as strong. You can buy these from sponosors---> or you can pick one up at a junkyard and have it built. ( Mine came from an 02 2500hd 6.0L truck)

~ As far as building the trans. I know this was asked alot. The 4l80e comes factory strong unlike the 4l60e so it doesnt take much in upgrades to make them bullet proof. In my trans I ordered a complete factory overhaul kit with all new seals, clutches, bushings, and etc.. Instead of using the factory clutches provided, I went with alto red eagle clutches. That is the only ugrade ive done.

~ 4l80e transmission mount

~ A custom made converter to fit the 4l80e but yet bolt up still using the mounting spots on the LS1 style flexplate. (I personally keep the stock LS1 flexplate) Right now the only two vendors I know or have seen that make the converter for this swap is Yank and Vigilante. Im sure there are others out there, but these seem to be the main ones for right now. Circle D also makes a converter for the swap now. The specs are below:

Custom Built 4L80 Multi Disk:
LS1 Bolt pattern
Billet Front cover and Billet Clutch
3 Disk Lock-Up - High carbon lining
Furnace brazed and tig welded
3 bearing design
245MM or 258MM Diameter choice.
Custom built for your car

~ You can use the stock flexplate. Ive also seen the TCI LS1 flexplate be used with this swap without any complications.

~ New transmission crossmember as the 4l80e doenst have the TQ arm mount on the trans anymore. The new crossmembers have mounts on the crossmember its self for the TQ arm mounting point. I used the one from yank. BMR also makes these. Im not sure is Spohn or UMI makes these or not. Supposedly the M6 crossmember can be modified to work. I have no more info on this, so if anybody does let me know and Ill add it.

~ Slip yoke for a th400 transmission. You have to becarefull with this one since there are 2-3 different types of output shafts on the 4l80e. Some have splines all the way up to and steel O-ring, some have splines that go half the way up, then theres a space then the steel O-ring. You'll have to reomve the tailshaft housing in order to see which one you have. The stock u-joint will be used with the new yoke and is a 1330 series. Also here is a link about different yokes for the 4l80e. https://ls1tech.com/forums/showthrea...ighlight=4l80e

~ The stock driveshaft will work, no need to lengthen or shorten it. One thing I did find was the once all was installed the yoke was about 3/4-1in to long. I called the place I got it from and they told me I could cut it with a band saw then bevel the edges. So far I havent had any problems with this.

~ The wiring harness, and harness adapter from speartech. The main 4l60e harness plug will not work with the 4l80e. Speartech has and adapter the plugs into the 4l60e harness then plugs into the 4l80e. The other harness that comes with the kit it the VSS plug. The 4l80e has two VSS senors on the drivers side and the stock 4l60e only has one. You will have to connect this to the actual PCM its self. then plug the new added harness into the FRONT VSS. If you plug it in the rear you are going to have idle problems. (been there done that, lol)

~ The PCM "WILL" control the 4l80e. Ive seen this alot on here where people say you have to buy a standalone contoler from TCI. If you want to go that route then thats fine but the stock PCM will control the 4l80e. You will have to have the PCM flashed with a new operating system. I simply pulled the .hpt or .bin file from my car, and also found a stock 4l80e truck .bin emailed it to Keith at HPtuners and he fixed it to reflect the new OS to control the 4l80e. You can have EFIlive do this also, but you, yourself can not make these changes.

~ 98 PCM's will not control the 4l80e. There are a couple alternatives for 98's. You could run a manual valve body meaning you shift gears yourself. Or you can control the 4l80e either with a TCI stand alone controller or the BS3. The BS3 has a module where you can contol any GM trans just like you would with HPtuners, EFIlive, or LS1edit. You could also swap out the PCM for a 99+ PCM then have the OS changed. (thanks obZidian!)

~ To save yourself alot of hassle and headache, go ahead and order the lokar flexible dipstick and dipstick tube from summit. I did not do this at first. I used a stock 4l80e dipstick tubeand dipstick that took over and hour of bending, twisting, and cussing to get it to fit. It will tuck nicely under the firewall and you'll barely see it. It worked out fine, but it botherd me knowing it was that tight in there, so I removed it and put the lokar flexible in. Took all of 5 mins to install the flexible tube. So id recommend you save yourself the hassle and go flexible.

~ Dust cover is optional, I chose to run one. Some choose not to run one. Its probably a good thing to run one in case you ever hit something on the road or etc.

~ Trans cooler if you dont already have one. The bigger the better.

~ Stock trans cooling lines will work if you modify them, or you could get some nice braided lines. Beings the connecting spots for the trans cooler lines are a little futher in placement from the 4l60e lines, I cut my stock lines, flared both ends a little, and placed a 9-10in rubber hose with hose clamps on each end to give me the extra length I needed. You will also have to bend the connection side a little to get the right angle coming off the trans. Also if you choose to run the braided hose or any aftermarket hose make sure you have the correct trans fittings

~ Stock shifter will work. I had to take the small bracket the where the shifter cable connects to the 4l60e and swap it out with the one on the 4l80e. Its the part on the trans where the gear changing occurs. The shifter cable will snap on this bracket. (sorry if it doesnt make sense) The part where the shifter cable attaches on the 4l80e is alot bigger then the 4l60e, but if you swap them out you'll be fine.

~ Cut the two ear's off the side of the bell housing to give you extra clearence. Even after doing this, you will still have to bang on the trans tunnel a bit with a sledge hammer to get the belhousing to clear. It sounds bad but its really not. Once you get that to clear, you will have to take a die grinder and cut a small square section from the trans tunnel bracing towards the rear of the trans. The main harness plug will need this room to clear. Without doing this the trans will not line up straight, then you'll never get the trans bolted to the crossmember and the connector will leak.

I belive thats all of it. Like I mentioned above if anybody has anything I left out let me know and ill make some changes. I know mightymouse had a link to some pics of the swap, if he wants I can add a link. Cablebandit aslo had alot of info on this.

Here is a price break down in what I have in mine. You may be able to do it cheaper, then again it may cost more.

~ Mightymouse's M6-4l80e swap with pictures: https://ls1tech.com/forums/showthrea...ighlight=4l80e


~ 4l80e trans from junyard- $600 shipped to me
~ Rebuild kit- $ 157
~ Build cost - Free
~ Converter and crossmember from yank- $1145
~ Lokar dipstick and tube - $80
~ Speartech wiring harness's- $169
~ Trans mount- $14
~ Slip yoke- $97
~ Dust cover/shield - $70
~ Trans cooler- $40
~ OS changed- $free

- you will also need a harness from an A4 since you are a manual currently.

This is all from Ls1tech and a link to the thread can be found here: https://ls1tech.com/forums/automatic...l80e-swap.html

[2.8 Bird]

That's a good write up there Mike. I always thought auto was stronger.

[LETZRIDE]

That's a good write up there Mike. I always thought auto was stronger.

I can’t take credit for that- I took that directly from LS1tech and shared it here- one of their members did a great job of pulling that all together

[ssms5411]

Nice write up, are you doing a 4l80e Mike? Ill stick with the 4l60e looks like too much work to do the 4l80e. Ill end up getting a tranny from performabuilt when im ready for $2400. Should last me for awhile. I see they mention Speartech thats who did my harness, I think it was $190 shipped.

[LETZRIDE]

Not at this time myself...but would certainly love to see photo's if Kevin2177 goes through with the swap!

[ssms5411]

With my 2008 truck with the 6.0 you would think it was a 4l80e but its only 4l70e had to look at the build sheet to make sure. Only 4 gears compared to the 6 in the 4l80e. Would of been nice to have.