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Old 10-11-2010, 09:25 PM   #29
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Originally Posted by choctawmel View Post
It's been a hard and bloody trek. But I've found a 4L80e. I'm going to UP-grade! The starter, fly-wheel, drive shaft will be deterrent. The emergency brake bolts to the tail shaft of the 545 and that will be a ???? the speed-o-meter is cable now and electric on the 4Ll80e. Many bridges to cross .
Glad to hear the Allison is on the ground and no trips to the emergency room were necessary. I think there is a version of the 4L80e that has the parking brake on the tail shaft. It may be as simple as buying the tail shaft housing. Is the output shaft size and spline the same as the Allison? Now the fun begins.

Good luck, Dan
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Old 10-12-2010, 07:27 AM   #30
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1986 34.5' Airstream 345
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Glad to hear the Allison is on the ground and no trips to the emergency room were necessary. I think there is a version of the 4L80e that has the parking brake on the tail shaft. It may be as simple as buying the tail shaft housing. Is the output shaft size and spline the same as the Allison? Now the fun begins.

Good luck, Dan
Going to look (I hope) at a 4L80 today. Some of the things I need to solve: Tail shaft to emergency brake assembly; Starter, bolts; Fly wheel; Speed-o-meter; Drive shaft; Cooler lines; Rear cross member; Shifter.
So, today I go to the starter shop, junk yard, and hot rod shop. The EPA is really ruining the old time junk yards.
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Old 10-17-2010, 05:18 PM   #31
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Got my 'TCI Transmission Control Unit' and wiring harness for the 4L80e I'm getting. Now this is a 'can of worms'! Spead it all out, read the instructions, scratch my head.
Yes a BIG can of worms!
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Old 10-21-2010, 07:17 PM   #32
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I'm still working on finding parts.
I orders a electronic speedometer.
Still haven't located a tailshaft housing (and shaft) with bolt holes for the drive shaft brake back plate. Can get it from GM, but $$$$. With the problem with the drive line brake and the cost of the parts, would of been cheaper to get a GM manufactured 4L80e from 'workhouse'. But I have a transmission now.
Nothing like a little cost overrun.
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Old 10-25-2010, 05:41 PM   #33
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I found a tailshaft housing and shaft and took it to my transmission guy Friday. Was hoping to get a call that it was done. But not yet. Been calling junk yards in search of the drive-shaft brake assembly. May go junk yarding (is that a word) tomorrow. Got my new electronic speedometer and it fits in the hole in the dash. Here's the stuff I've got now.Click image for larger version

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See that box of worms?
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Old 10-26-2010, 07:17 PM   #34
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Went 'junk yard'n' today. Found a Ford drive shaft brake. The guy really tried to tell me, "All you need is a 4 bolt to 6 bolt adepter and this will work."
Anyone know of a good RV grave yard?
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Old 11-09-2010, 05:15 PM   #35
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My transmission transplant is still working. I just can not find the 'E-brake' to fit the heavy duty tail shaft housing. I did a backup today and an going to the 'medium duty' tail shaft housing. Two junk yards I went to today are looking for the same 'heavy duty' e-brake as I am. So, the 4L80e is going to get another tail shaft and housing.
Maybe I'll change the oil while it's up in the air.
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Old 11-10-2010, 02:29 PM   #36
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Today was a good day! I exchanged the heavy duty tail shift housing for a medium duty and the 1st junk yard had the e-brake to fit. The pictures not much, but I've been on hold till I found it.
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The junk yard cut the cable right at the back plate.
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Next stop is the car wash for these finds! Then to figure out the cable.
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Old 11-19-2010, 06:08 PM   #37
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Bet you thought I'd give up. Well I just got my 4L80E on the floor in my barn. It's 3 7/8 inch longer than the Allison 545.
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I've got it just in time to not have time to work on it till after Thanksgiving.
I'm ordered a dip-stick and tube and speed p/u. May get the deep pan too.
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Now that's the worms out of the can!

I had just started work on installing the new speed-o-meter and for some reason, I lost dash power. I moved the dash, so something came loose. That's the other can of worms!
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Old 11-23-2010, 08:42 PM   #38
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Were we go! After more trips to the hareware store than I want to admit I got the right metric bolt with the right pitch to fit the tail shaft house. I hate metric! Who ever figured that system out should of been be-headed!
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No one was looking and I got the tranny in!
Had to grind the corners off the cross-member, but it's in.
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Went to put the e-brake on and the cross-member is backwards. I'm going to be drilling some new holes in the frame either way it goes. That don't look like fun.
Got my dipstick and speed pickup today. Orders a deep pan with cooling fins just for good measure.
I'm keeping a cost total and it's 'in budget' so to speak. Think the only big thing left is the drive line and that's going to run around $200 with all the u-joints being replaced.
Still don't have 12V to the dash and at some point I got to fix that.
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Old 11-27-2010, 05:55 PM   #39
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Had some time and crawled under Silver Bullet today. Got the drive line all removed. The drive shaft shop need the complete set to rebuild it. Took one measurement from the yoke on the tranny to the front carrier bearing. Going to have to draft some help to measure from the yoke on the tranny to the yoke on the rearend. Arms not long enough. It was time to get it all out. All the u-joints and the two carrier bearings need replacing. May as well get it all done as I going. Got the e-brake in stalled.
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Don't it look cute all clean and new.
I spend about 3 hours under there and I'm real for a beer! Or two, or four
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Old 11-30-2010, 07:19 PM   #40
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Today I hooked the shifter up. It's pulls and it needs to push. It has 7 positions and I need 8. The travel isn't long enough to go to all the gears. Dang! I email the maker of the shifter I got, no reply, so I call them. Don't make a shifter for the 4L80e.
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I call 5 shifter makers. Same story. So, I rip the shifter out, tore it apart, take the gear lock loose, change it from a pull to a push. drill another hole in the side console for the cable. Pull the shift arm off the tranny. They make am adjustable arm, so I CAN make this shifter work. It will just be a 'Mastery Shifter'
The chassis battery died, so I got a new one. Don't know why my 2003 battery gave up, it was only 7 years old.
I check my email and Orscheln (the shifter people) tell me they have a shifter that will work. I call, it's too late... Tomorrow!
With that on hold I install the new deep tanny pan.
It's Miller time!
Tomorrow my drive line should be ready!
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Old 12-02-2010, 12:36 AM   #41
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Wow, have one for me too... Why do these things have to be so tricky!
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Old 12-02-2010, 01:00 AM   #42
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These little challenges are what makes it fun and keeps the job interesting.

Cheers, Dan
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