[grivera]

I bought a Hughes 4l80e (91-96 model) via Jegs on March 3 and it arrived this past Tuesday, May 5. The trans was well packaged, comes with cast aluminum pan and a dyno sheet. I’m starting install into the 69 bird but have other projects in play as well so will do install in stages. I bought a Jegs brand dipstick and Summit brand BOP to Chevy adapter plate. Also bought the U.S. Shift Quick 4 Gen II controller and a TSP 3200 stall converter via Cliff Ruggles. Other parts include a Shiftworks 68-81 Firebird Factory Shifter conversion kit which includes the custom detent for the overdrive. And the G-Force x-member as the trans mount position is moved back some.

Many thanks to Larry (Formulajones) and Mike (HWYSTR455)who’be answered lots of my questions along the way- I’m sure I’ll have more.

On Mike’s advice I dry-fit the dipstick tube and the adapter plate on the engine and the trans. Thank goodness cause I had to clearance the plate due to interference with the dipstick tube - would have sucked to deal with that while installing. I am painting engine side of the plate Pontiac blue and trans side gloss black to match trans.

I got a the mechanical speedometer gear tailshaft housing and painted it gloss black to match trans and put the drive gear on the tailshaft. It has set 4 tiny screws to hold gear on which get red lock tight. You can see housing on floor. This type of housing is necessary to use a mechanical speedometer with an electronic trans - other ways to do it but I chose this route.

The difference in length between the TH400 and 4l80e is about 3.5 inches (28.25”vs 31.75”) and adapter plate is just over .141" so not too bad. Also, the bottom front of 4l80e is 1” wider than the TH400. I’ll update this post as I move along.

I bought the mechanical housing from eBay seller alloy_specialties who has been a pleasure to deal with.

Hughes 4l80E: https://www.jegs.com/i/Hughes-Perfor.../25-1/10002/-1

G- Force Crossmember: https://www.speedwaymotors.com/G-For...caAu2mEALw_wcB

Tailshaft housing: https://www.ebay.com/itm/22409497191...mis&media=COPY

Dipstick: https://www.summitracing.com/parts/s...XVsXgQtLS7WU5h

Adapter plate: https://www.jegs.com/i/JEGS/555/6017...8aAnsPEALw_wcB

Shifter conversion kit: https://shiftworks.com/collections/f...conversion-kit

[punkin]

Thanks for the write up. Have you tackled determining which gear you'll need for the mechanical speedo yet?

[grivera]

The tailshaft housing from alloy_specialties comes set up with both gears. I had to provide tire diameter (26.5) and gear ratio (3.55) at time of the order.https://www.ebay.com/itm/22409497191...mis&media=COPY

[grivera]

Most of the install thus far has gone ok and I got the transmission into place.

TSP welded spacers to the torque converter mounting points and the snout to account for the trans to engine adapter which is .141". It was pretty easy to seat the converter but I stood it on vertically as well to make sure it was fully seated. Everything fits well together and the gap between flex plate and converter pads is right about 5/32.

I put trans in with dipstick tube installed - I found it easier to partially install the top transmission to engine bolt to hold the dipstick in place. Doing this also kept me from fighting to get the bolt in place after the fact and the slight tension from the dipstick tube bracket held the bolt in place.

I ended up using banjo fittings at the trans with partial lines to meet the factory trans lines so I wouldn't have to fight the little clearance between the trans tunnel and trans fittings. For connection to the trans banjo fittings I used 5/16 to -6an compression fittings I decided to route the lines at trans as pictured to clear the dipstick tube bracket and the bump on trans.

I ran into an issue with the G-Force crossmember - it interferes with the exhaust at the x-pipe. I will have to move the x-pipe assembly back by about 4". Of course I have to get check drive angle and have the driveshaft cut before I can check if it will interfere with the new position of the x-pipe.

More to come.

[grivera]

Couple more pics - view of tail hosing from rear and converter to flex plate clearance. Not sure why the pics rotate when posted.

[Formulajones]

Glad to see this coming along Will. It's going to be a completely different car when finished

[69FIREBIRD76MM]

Very nice, I installed 4l80e in my 69 bird but I can only go 3.50 rear gears to keep rpm's decent on freeway. 3.73-430, 4th gear is .83 which is not great.

[Formulajones]

I run a 4L80E in one of the cars here with 4.10's and a 28" tire. It's actually pretty nice. With the .75 overdrive and the converter locked, 65 mph is only 2400. It'll still loaf along 75 mph pretty comfortable.

After driving it 35 years with a 400 turbo and 4.10's it's like a completely different car. Night and day.

[grivera]

I welded in Walker exhaust connector pipes to stretch the head pipes, thereby moving the x-pipe back to clear the crossmember

[Formulajones]

I see you used the same type or brand of cross member I bought and used in my Chevelle.. Looks like a G-force.

That thing is a beast. I used 1/2" bolts to mount it. Because of it's beef I also had to move my X-pipe back on the Chevelle about 6 inches.

On dad's GTO I just used the original cross member on his which worked out fine, and was able to leave the X-pipe alone.

[JLMounce]

I'd be interested to know as well weather the F-body th400 crossmember would work with the 4l80.

[Sirrotica]

Saw this on the camaro site using a CE kit, post #11:

https://www.camaros.net/threads/cros...-4l80e.149181/

Another discussion at LS1 tech for 70 Nova crossmember for 4L80E:

https://ls1tech.com/forums/conversio...70-nova-2.html

Speedway Motors 69 F body crossmember selection here:

https://www.speedwaymotors.com/Searc...%20crossmember


FWIW, I cut and reversed a T350 crossmember in a 76 T/A to use a long tailshaft T400 in it, If you can fab stuff you should be able to make a stock one work with cutting and welding.

[Formulajones]

Yes, in instances like that I cut the mounting tab off and reweld it on the back side of the cross member. I've done that on 2nd gen F-bodies and 68-72 A-bodies. Only thing you might run into depends on the type of pan used and pan clearance as now the crossmember runs between the pan and mount.

The 1st gen "might" be a tad different but don't see why it couldn't be done that way. The only 1st gen I have here isn't a 4L80 example, it's a manual and has a 5 speed, and I ended up buying a crossmember as I didn't want to attempt modifying the original. But it looked doable.

[grivera]

Originally Posted by Formulajones

I see you used the same type or brand of cross member I bought and used in my Chevelle.. Looks like a G-force.

That thing is a beast. I used 1/2" bolts to mount it. Because of it's beef I also had to move my X-pipe back on the Chevelle about 6 inches.

On dad's GTO I just used the original cross member on his which worked out fine, and was able to leave the X-pipe alone.

Yep - it's a G-Force. I used the supplied 1/2" bolts so I had to ream the bolt holes. It is a beast - definitely overbuilt. It is tricky cause I also have the driveshaft loop and trying to get proper DS angle. The G-Force crossmember seems to sit lower at the trans mount area so I had to shim between the mount and trans to get the DS some clearance in the loop.

Originally Posted by JLMounce

I'd be interested to know as well weather the F-body th400 crossmember would work with the 4l80.

It would require some fabrication cause the subframe is recessed where the crossmember is bolted and limited in room.

[Formulajones]

Have you driven it yet?

[grivera]

Originally Posted by Formulajones

Have you driven it yet?

It's a ways from being roadworthy as I'm also installing Vintage Air, redoing fuel lines, interior work, sound deadener, dashpad, gauge cluster, and general mission creep. Likely about 25-35 hours of work left but it's all after work hours...

[JLMounce]

Any updates?

[grivera]

Getting there - I've fully installed the VA minus refrigerant and did start up this past Friday. Still need to install the fender, hood, center console and seats - and create a tune for trans controller.

[JLMounce]

Early impressions, are you satisfied with the Hughes trans? I'm trying to get a 4l80e built right now, but the local shop I've been working with, and myself, are having a hard time finding a rebuildable core.

[grivera]

I've only "driven" it several feet in my shop, hahaha. Everything from the ordering process, communication, estimated build time, shipping time/packaging was great - and the tech team at Hughes answered all my questions with professionalism - even the stupid questions. They always answered the phone or called right back. The trans came with a very nice powder coat, a cast aluminum pan and all new parts - looks like a brand new trans.

I originally planned to have a local guy, Wayne Rogers from Rogers Automotive in Manassas, VA build it as he comes highly recommended and supposedly builds for some of the Street Outlaws. Unfortunately he had excuse after excuse for 3 months straight of why he couldn't start the build - wasted lots of time with that dude and maybe for the best. Eventually I stopped calling and ordered from Hughes in large part based on Larry's (Formula Jones) recommendation as he's purchased several from Hughes. Of note, prior to calling Hughes I also called CK at least 3 times and still waiting on a call back. Jakes Performance answered their phone and spoke with me but their lead time was about 5 months.