4L80E/241 Combo

[pomai]

I need help!
the 241 wont mate up with the 4L80E trans, there is approxemently a 1/2" gap. I removed the adapter and slid the transfer case on to see what is the cause.

I hope that the pictures will explain better then I can, my problem.
wrong output? input? adapter? What's Wrong?

Thankk You,
Ed

 

[6872xtc]

I have a 2001 4L80E/NP263 here. The adapter is 2.48 thick. The tail shaft splines 2.78(?)
That's all I can tell you, trans is obviously torn down right now.

 

[skunked]

IIRC the shaft stick out should be 2 & 7/8”. ORD covers most of this on their tech page.

 

[sweetk30]

You have a full spline 2wd shaft cut down . Thats the problem .

Look at yours and the pic posted by 6872xtc of a TRUE 4x4 shaft .

You have 2 simple options . Clocking ring as a spacer . Or cut the 241 input gear nose off a tiny bit .

I had to cut down my 203 input for this EXACT problem . Its all in my 203/205 doubler thread in the advanced section here .

 

[pomai]

You have a full spline 2wd shaft cut down . Thats the problem .

Look at yours and the pic posted by 6872xtc of a TRUE 4x4 shaft .

You have 2 simple options . Clocking ring as a spacer . Or cut the 241 input gear nose off a tiny bit .

I had to cut down my 203 input for this EXACT problem . Its all in my 203/205 doubler thread in the advanced section here .

 

[sweetk30]

https://ck5.com/forums/threads/4l80...icked-its-all-done.253000/page-2#post-2553457

here is the specific thread and pics .

correct / true 4wd shaft

your 2wd shaft with NUB RING

full length spline 2wd shaft un cut . notice the NUB RING

 

[pomai]

Thank you everyone for your help.
Sending the Trans & transfercase back to make it correct, All the way from Hawaii.
Thanks again,
Ed

 

[sweetk30]

problem should be just the trans shaft .

and at this point just use a clocking ring as a spacer and be done with it .

but up to you and good luck on the project . glad we could help .

and how did it get the 2wd shaft in it when built for 4x4 ? if we can ask . and who built it ?

 

[sweetk30]

get ahold of kirt / @cybrfire vendor here for this and get it with out hardware . https://diy4x.com/product.php?productid=17741&cat=247&page=1

just make sure to ask him how thick it is for the gap you have .

 

[pomai]

Are there different length 32 spline input shafts for the 241C transfercase?
I seen 2 different size bearings for it but have not seen different lengths?

Thank you,
Ed

 

[Hogback Fabrication]

There are not different length 32 spline inputs as far as I know.

Maybe trim a little off of the input on the t-case and output of the trans? Looks like you'd still have plenty of spline engagement.

 

[sweetk30]

i have been beating my 203/205 doubler with the cut down 203 input from the doubler thread i linked here now for 2 years . even had the unit out for other problem and no signs or wear or cracking .

since your way out there i would do the clock ring and if any extra needed trim a tiny bit off the input gear .

unless your builder screwed up and is admitting this and covering the shipping both ways and you can live with the down time then you have a few solid options in this thread .