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t-case selection for 5.3 with 4L60e

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75K5

1/2 ton status
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I recently bought a damaged 09 tahoe with 900 miles on it and pulled the powertrain to put in my 75 blazer. The 09 tahoe was a 2WD model, and I removed everything from the truck (down to the fuel tank and E85 gas cap/filler). The transmission has a 27 spline output shaft.

My 75 Blazer has a 350 with a NP203 and locking front hubs.

Here are my goals:
  • would like to use this adapter because it has the VSS sensor built in
  • would like to end up with part time 4WD
  • would like to avoid changing the output shaft in the transmission

what would you recommend? Here are some options I am considering
  1. keep the 203, get a part time conversion kit
  2. find a 27 spline 205 (not sure what year range they existed)
  3. 90-91 k5/burb 241
  4. other?
 
Currently it's just the weekend driver. There's no serious rock crawling, just the occasional offroading.
 
IIRC the 4L60E DOES NOT have a removeable tailhousing after 1996 so you would have to use a divorced t-case. :deal:

This means your options are far and few between as far as a t-case goes.
 
If you decide to go the 205 route, I have a 27 spline I'm gonna use for a doubler...I'll be building it with a 32 spline so I wouldn't need the 27. Don't imagine it's worth shipping the whole case to you though.

I also vote for the 241 though. I love the ones in my 96s. If my 76 had one already, I probably would not bother with a doubler.
 
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I think I remember what changed now that I thought about it some, the tail housing changed from a 4 bolt (700R4, 4L60, 4L60E up to 1995) to a 6 bolt like the 4L80E and also uses a removeable bellhousing as well.

Sorry for the confusion on my part.
 
What trans is in the 09?

Is a 4 speed even available in 09? I was thinking it was a 6.
 
dhcomp said:
What trans is in the 09?

Is a 4 speed even available in 09? I was thinking it was a 6.
Click to expand...

Both were offered from what i've read BUT the 4L60E was only available in 2wd models with the 4.8 engine so that leaves me wondering if his engine is a 5.3 or the trans is a 6L80.
 
4X4HIGH said:
Both were offered from what i've read BUT the 4L60E was only available in 2wd models with the 4.8 engine so that leaves me wondering if his engine is a 5.3 or the trans is a 6L80.
Click to expand...

Yah, exactly. Something seems wrong.
 
4L60E was available with 5.3 in 2009. You will need to change the output shaft to a shorter 27 spline 4x4 version to use any bolt on transfer case. There are factory trans to transfer case adapters for the 6 bolt 4L60e that will fit up to the 241 if you want to go that route. I think overall that would be the least expensive and surest fitting
 
yea, I wished it was the 6L80E but when I actually removed it, I realized it was just the 4L60E. The vehicle was a 09 tahoe 5.3 Police Pursuit vehicle. The trans does have a 27 spline output shaft though.

Greg, let me make sure I understand this. Is it correct that I will not have to change the output shaft if I use one of the transmission adapters like this one:
http://advanceadapters.com/product/2322/50-0405.html

Thanks,
Brian
 
75K5 said:
yea, I wished it was the 6L80E but when I actually removed it, I realized it was just the 4L60E. The vehicle was a 09 tahoe 5.3 Police Pursuit vehicle. The trans does have a 27 spline output shaft though.

Greg, let me make sure I understand this. Is it correct that I will not have to change the output shaft if I use one of the transmission adapters like this one:
http://advanceadapters.com/product/2322/50-0405.html

Thanks,
Brian
Click to expand...

Yes, you will still need to change the shaft, but if you use the 241 TC with speed sensor you will NOT need the adapter set up you have linked to, as the TC will already have that installed. I can get you into the shaft and TC adapter pretty reasonable if you can't shake one out locally. I have a couple of 241's with speed sensor but they are both off 4L80E's and use the big input spline.
 
Yea,you must change the output shaft which means tear down time:doah:.
Also GM offers a adaptor for a 241 for about $75.
I just went through this same affair about 6 months ago with my conversion.
 
bummer, nothing like tearing apart a transmission that has 900 miles on it!

I wonder if I can find a 6L80E for a decent price. If I have to mess with it, that's the way I really wanted to go...
 
OK, I've come up with another question! I found a 6L80E 4WD transmission with the transfer case attached. It's a drivers side drop (obviously) with electronic switch.

I like this idea a bit because using a switch to shift would be nice. Has anyone converted their K5 from passenger side to drivers side? Thanks for the insight!

Brian
 
well I couldn't come up with a 6L80E, but I did come up with a 4L60E 4wd transmission and transfer case for a good deal from an 07 silverado. This gives me two more questions

1) If I understand this thread correctly, I could use the 4WD 4L60E transmission and directly bolt it to a 241TC with speed sensor. Correct?

2) The other option is to try and use the transfer case that is bolted to the 07 silverado transmission. It has the front axle connection on the drivers side. This might be a good excuse to upgrade the front axle. Are there any bolt-in axle swaps that could give me the drivers side connection?

Thanks,
Brian
 
75K5 said:
well I couldn't come up with a 6L80E, but I did come up with a 4L60E 4wd transmission and transfer case for a good deal from an 07 silverado. This gives me two more questions

1) If I understand this thread correctly, I could use the 4WD 4L60E transmission and directly bolt it to a 241TC with speed sensor. Correct?
Click to expand...
Others can answer for sure but I believe a '89 241 will bolt on. Not sure on the output shaft though.
2) The other option is to try and use the transfer case that is bolted to the 07 silverado transmission. It has the front axle connection on the drivers side. This might be a good excuse to upgrade the front axle. Are there any bolt-in axle swaps that could give me the drivers side connection?

Thanks,
Brian
Click to expand...
No. Ford axles would work but you'd have to move perches and stuff. Has been done before.
 
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