Baumann Optishift Install- 4L80E

[Kenny78]

Here is my install of the new Baumann Optishift controller in a 1982 K20. I got a 1995 K3500 4L80E from a junkyard.

According to internet resources, there is supposed to be a reluctor ring in 4L80E's up to 1996 (mine didn't). Apparently during rebuilds they are prone to breakage and left out (just so you know if you do this). So I had to become creative, tear down the transmission, or find a 1990-1991 3/4 ton NP241 transfer case. Well I obviously did not want to tear into the trans (it requires complete disassembly) that I have a 30-day guarantee on and looked for a NP241 quietly while searching another way. While searching the internet I came across this http://www.jagsthatrun.com/Pages/Parts_S10-Reluctor-Diff.html. Well I called them to see if they made a ring for 1350 yokes and they do not. The reluctor ring uses 40 pulses per revolution so I needed to find a 40 tooth sprocket. I found one at my local Allied Bearing and I had to cut off the hub only to later find that Wholesale Tool sales one without a hub (make sure your sprocket is of a ferrous metal). Nothing that a plasma cutter and a dremel can't handle to cut a hole for it to mount around the yoke roughly following the "jags that run instructions" (sorry I forgot to takes pics before I installed). The sensor and jamnut details can also be found in those instructions.

Next obstacle was the throttle postion sensor. I didn't want to pay for the pre-made kit from various places. So I made my own out of scrap and an old TV cable. I used a sensor from a 1985-1991ish Z28. If you can build a bracket to swing the opposite way you can use the TPS off the same era V-6 camaro. On my used TV cable the trans side pulled off and allowed me to make it a custom length. I was concerned that drilling through the arm to attach the cable wouldn't leave enough swing so I used a brass cable stop (you feed the cable through and a bolt keeps the cable in place). I welded a cutoff bolt onto the arm and that provided me a place to put the cable stop.

Here is the TPS bracket (The wiring on the TPS is temporary I just needed it to confirm that it works)

Reluctor ring

 

[4X4HIGH]

I envision that "reluctor ring" to get damaged pretty quickly if this is for a wheelin rig.

 

[Fordum]

If you have tried it and it works, OK.

But I'm afraid that you are going to have to adjust that sensor.
I have worked with a LOT of prox sensors, and they need to see a definite break in the ferrous metal.

It looks like, from the angle of the pictures, that the sensor is too "deep". It will see too much of the body of the gear.

Ideally, you want the bottom of the slot between the teeth to pass by about the bottom of the end of the sensor. Just the teeth should go by the end.

Otherwise, you will get erratic results. It may not count at all, or it may skip teeth.
If it skips teeth reliably, then it will work, your speed will just read low. Otherwise, the speed and cruise control may jump erratically.

 

[Kenny78]

Baumann Optishift Install- 4L80E continued

A background info, I decided to put a 4L80E in my truck because it is a hauler and driven mostly highway. I did not like the 4:10 gears and TH400 (equals around 3250rpm at 65mph). I searched for a 1991 4L80E with stand-alone controller but apparently not all 1991's were stand-alone. The TCI, Compushift, etc... are expensive and I didn't like the Gear Vendor price either. I came across Optishift and found out on a Mustang forum that they had a group buy. Long story short is that we have an optishift at an unbelievable price. Thanks Baumann

You can order the controller by itself or with a harness. I got the harness with the group buy. I had to make my own lengthened VSS wire. The software is easy to use just put in your CD-ROM, install, and go. There are pre-loaded transmission settings based on your transmission (4L60E, 4L80E, and some Ford transmissions).

The controller shows on a 3 character LCD screen; temperature, gear selection, TCC status, TPS voltage, speed, and you can store 2 tune settings. It also show fault codes and will go into limp mode if need be. Obviously you can tune in real time with a laptop. When your laptop is hooked up it shows shift points, commanded pressure, and all of the vitals.

We got the one with the built in tuning interface but the laptop is more advanced for tuning your transmission.

Also I had to move the crossmember back a little over an 1", the frame mount of the gear shift needed to be moved back and the gear and 4wd shift linkages need to lengthened. Note that if you use a NP208 adpater you will need to machine .060" off the indexing ring.

It drives nice down the highway with 4 speeds.

I am planning to mount the controller under the dash in the center. I also added a drain plug.

 

[Kenny78]

On the reluctor ring, don't worry its not a wheeler and its temporary until I rebuild the transmission.

Must be the angle of the pictures because we have driven 200 miles since Tuesday night with constant speed on both the mechanical speedo and the electronic speedo in the controller.

 

[yellowK20]

I searched for a 1991 4L80E with stand-alone controller but apparently not all 1991's were stand-alone.

Only the diesels have the stand-alone controller

 

[Kenny78]

Only the diesels have the stand-alone controller

Not according to some reliable sources, but it doesnt matter to me anymore Also the diesel stand alone's are 91-93. I almost bought a 93 6.5 turbo truck and swapped the engine/tranny but backed off because I didnt want that much of a project.