Powertrain swap from 2001 2500 6.0 L w/4L80e to 2007 (new) 1500 5.3L w

[BustedKnuckl]

I have a 2007 1500 (new body style) 5.3 L 4wd with and 4L60e transmission. I removed the t-case for what I thought was a bad bearing on the input shift of t-case.

 

Once I had the t-case out though I realized the squealing was coming from inside the transmission. I'm looking for a replacement transmission to swap mine with, hoping to find one local that is used.

 

I do have a 2001 2500 6.0 L (4L80e trans I believe?) sitting the in the back though, and my question is whether it's a viable option to swap the powertrain from the 2500 into my 1500, and what kind if modifications a project like that would include. Every "5.3 to 6.0 swap" search result I can find seems to be more in relation to swapping in newer LS4 and LS9 engines.

 

I guess I should also add that the 5.3 powertrain has 346,000 km on it, and I'm worried that I will no sooner replace the transmission and I'll have a motor grenade on me. The 6.0 powertrain has 180,000 km on it.

 

So, long story short I guess, is it possible? Is it worth it?

 

Thanks

[BustedKnuckl]

Edit: the 1500 is a GMT-900 and 2500 is GMT-800. Also the search results I get back for 6.0 L swap are for L4H and L9H not LS4 AND LS9.

[NSFW]

Right off the top.

The 4L80e is longer then the 4L60e.

The front differential housing is a bit different on the 2500(assuming they are both 4wd) then the 1500 and you would need a longer front drive shaft to get it all to connect. The pinion on the 1500 has shorter reach then the 2500's.

The input primary on the transfer case would need to be changed from 60e spline/inner diamater to 80e spline/inner diamater to bolt up to the transmission. This requires blowing the transfer case apart right down to the 4low planetary. But its pop out one and drop in the other. They are both the same size and match eachother perfectly. I know this 1st hand.

No change with the transmission mount as far as I know but as the 80e's is larger, migrating the mount from the 2500 to the 1500 wouldn't hurt, given its not too extensive.
The rubber mount might have to be turned the other way (spin 180) (built in offset) to make up for little differences. One bolts to the frame from the bottom, the other is cradled by the frame rails.

The 4L80e cooling lines would need to be migrated over over from the 2500. They are larger diameter and permit higher flow rates. bring the cooler also.

Outside of the above.. shifter should button up no problem. The vehicles speed sensors, and auto 4wd sensors are all on the Tcase and you are retaining that part.
So the transmission would just need to be told when to shift, connect to the Serial Buss somehow, and when to lock up the TCC etc.

The oilpan on the 80e is larger then the 60e, Larger length-ways.. but not any deeper then the 60e. Not sure how this would interact with the 5.3L exhaust tube as the 6.0L turns down before the oil pan, under the bell housing. Where the 5.3 goes under the pan.

Also not sure if the shift arm support brackets are in the same place on the trucks, or not. Might be moved a bit back. Or the distance between the arm and the braket are the same.. just further down the transmission housing on the 80e.

Actually mentioning that. WHILE you have the transmission out, swap out the star bolts that secure the transmission shift rod bracket for some metric hex head bolts. Saves it down the road if you need to do a filter change, as its a PITS to get off.

I'd look much closer into that electrical, might be able to get away with it, by re-arranging the pin out to match the GMT900 harness. Could work?



Recently I have learned that the data communication aspect of the GMT900 changed a few things between the GMT800, not sure if that was included.


Hope this helps you get a better idea. 60hrs and I bet it would be good as new.