TransGo 4L80E-3 Reprogramming Kit Installation and Upgrade Guide

Step 1: Drilling Valve Body Passages

Locate the 'X' marks on the valve body at the angle shown. Center punch the marked areas, then drill through the partition with a 0.125 inch drill bit. Subsequently, enlarge the hole with a 0.187 inch drill bit. Drill sizes are detailed on page 5.

Diagram Description: Two images show the valve body. The first, 'Step 1 Enlarged', shows drill bits near 'X' marks. The second, 'Step 2 Enlarged', shows a white dot on a passage.

Step 2: Drilling Accumulator Passage

Remove the Accum Valve (refer to Step 3). At the white dot location, drill down through the bottom of the passage using a 0.093 inch drill bit. Ensure all drill chips are cleaned out from steps 1 and 2.

Drills Provided: 0.093, 0.106, 0.125, 0.187 inches.

Step 3: Accumulator Valve Replacement

Discard the original Accum spring and plug. Install the Accum valve, followed by the new BLUE spring, and then the new plug with an O-ring. Ensure the new end plug is installed with the threaded end facing outwards.

Diagram Description: An illustration shows a new steel plug and O-ring, a blue spring, and the Accum Valve.

Note: Do not connect any wires to the valve body sensors or switches. If the vehicle has wires connected to the transmission, disconnect them and secure them away from the work area.

Step 1: Install Relief Assembly Cover

Install the relief assembly cover using two valve body bolts and the provided nuts, tightening them finger tight. Drill a 0.187 inch hole in the 'Mid Hole' location through the valve body casting. Clean drill chips from both sides of the valve body upon completion.

Diagram Description: An image shows the valve body with labels for 'Valve Body Bolts' and 'Mid Hole .187 drill'. A smaller inset shows the 'View from Other side when finished'.

Step 2: Remove Solenoids

Remove the Pressure Control Solenoid and its bracket.

Diagram Description: An image shows the removed Pressure Control Solenoid and Bracket. A label indicates 'TCC PWM Solenoid Re-use'.

Step 3: Prepare Relief Valve Assembly

Prepare the relief valve assembly for installation (refer to Step 2 on page 8). Install the YELLOW spring onto the stem end of the valve. Push the stem end of the valve up through the cover while a helper installs the "E" clip. Exercise patience during assembly, as small parts can easily be lost.

Diagram Description: An illustration shows the 'Relief Assembly' components: 'Relief Valve', 'Yellow Spring', and 'E-clip'. The cover is shown with the 'TransGo logo facing UP'.

Step 1: 3-4 Shift Valve and Spring Replacement

Remove the check ball sleeve, 3-4 shift Valve, and Spring. Proceed to Step 1A, then continue with Step 1. Discard the original 3-4 Shift Valve Spring. Re-install the 3-4 shift Valve. Place the PLAIN Spring into the 3-4 shift Valve bore, between the 3-4 shift Valve and the Check Ball Sleeve.

Diagram Description: Two types of shift valves are shown: '1st type' and '2nd type'. The '3-4 Shift Valve' is depicted with a 'Roll pin'. A note states: 'Flat side out. Roll pin does NOT go into hole!!'. The 'Check Ball Sleeve' is also shown.

Step 1A: Drilling for 3-4 Valve

With the 3-4 valve removed, drill a 0.093 inch hole through the valve body at the white dot location.

Step 2: 2-3 Shift Valve and Solenoid Replacement

Discard the original 2-3 shift Valve Spring. Install the new RED spring onto the roll pin end of the valve. Discard both shift solenoids.

Diagram Description: Illustrations show 'Discard' components and the '2-3 Shift Valve' with a 'RED' spring.

Step 3: 1-2 Shift Valve End Plug Installation

Install the new 1-2 shift valve end plug and retainer bracket after the roll pin.

Diagram Description: An illustration shows the '1-2 Shift Valve', a 'Reuse' spring, and a 'New end plug & retainer'.

Step 4: Tapered Plug and Spring Installation

Install the Tapered plug with O-ring, Filter, Orange Spring, and the new end plug. If the end plug's roll pin does not align with the pin hole, grind 1/16 inch off the filter.

Diagram Description: An illustration shows the 'Tapered Plug With O-ring', 'Remove Filter O-ring', 'ORANGE' spring, and 'New end Plug'. A note indicates 'Grind here If needed'.

Step 1: Prepare New Separator Plate

Discard the original separator plate and drill holes in the new plate according to the desired shift firmness.

Hole Selection Guide:

• ABC: Comfort = 0.076 inches
• Firmer = 0.093 inches
• AB: Off Road & Hot street = 0.125 inches
• AB: With high stall converter = 0.125 inches
• Hot street & High stall make "C" = 0.106 inches

Diagram Description: An illustration shows the separator plate with labeled holes (Z, C, B, A). A list of 'Drills Provided' includes sizes: 0.187, 0.125, 0.106, 0.093 inches. A note states: 'During assembly install "Z" bolts first.'

Step 1: Valve Body Assembly Details

Note: The primary change on this page is replacing the 3rd Accum spring. Other steps are for re-assembly.

A. Discard the Original 3rd Accum spring. Install the NEW WHITE spring.

B. Install the gasket onto the accumulator housing.

C. Install the TransGo full-size gasket and the separator plate onto the valve body. Align the plate and gasket by inserting bolts into holes marked "Z".

D. Install the accumulator housing and tighten the bolts.

E. Pull out the "Z" bolts. Apply a small amount of oil to the plate and place the Case gasket on the plate, aligning it carefully at the "Z" holes.

F. Apply a small amount of assembly gel to the holes for the check balls and place seven 1/4 inch balls into the holes.

Diagram Description: Illustrations show various springs ('Reuse Original 8 coils', 'Reuse Original 10 Coils', 'PCS Accum', '4th Accum', 'Install New White 3rd Accum Spring', '3rd Accum'), the 'Accumulator Housing', and the 'Valve Body'. A label indicates '© = 7 Check balls'. Another note states: 'Supplied case gasket has enlarged hole here and must be used!' A note on the 'Valve Body' states: 'During assembly install "Z" alignment bolts first.'

Step 1: PR Valve Installation

Install the new PR springs, washer, boost valve, and bushing. For the 'No Stem Type 2 PR valve', do not install the spacer. For the 'Stem Type 1 PR valve', install the spacer on the PR valve stem.

Diagram Description: Illustrations show components for the PR valve assembly: 'Snap Ring', 'Bushing', 'Boost Valve', 'Washer', 'Pur-', 'Install NEW Purple spring', 'PR Spring', 'Stem', 'Spacer'. Two types of PR valves are shown: 'Type 2 PR' (No Stem) and 'Type 1 PR' (Stem).

Step 2: Install Stronger 4th Bolt

Install the new, stronger 4th bolt and washer.

Diagram Description: An image of the valve body shows a 'New 4th Bolt' being installed. Several 'C' marks indicate check ball locations.

Step 3: Servo Piston and Spring Installation

Remove the Servo cover and piston. Install the new ORANGE Spring. If the new spring does not fit, re-use the original spring.

Diagram Description: Illustrations show the 'Servo cover and piston', 'Gasket', 'Reuse 2nd Coast Servo', and the 'Orange' spring. Labels indicate '1-2 Accumulator Piston' and 'L/R Band Servo Piston'. A note states: 'No Balls Here.' and '© = 7 Checkballs'.

Step 1: TFP Switch and Bolt Installation

Install and tighten the "Z" bolts first. Re-install the TFP switch assembly, ensuring O-rings are in place, and then install and tighten the remaining bolts.

Diagram Description: An image shows the valve body with 'Z' bolt locations indicated. The 'TFP Switch Assy.' is shown separately.

Step 2: Relief Assembly Installation

After tightening all bolts, remove two bolts and install the relief assembly. Discard the dip stick stop bracket if equipped.

Bolt Torque: 95 - 100 Inch Lbs.

Seating the Relief Valve: When bolts are tight, gently tap the relief valve with a small hammer and a 1/4 inch punch 2-3 times to seat it.

Diagram Description: An image shows the 'Relief Assembly' being installed onto the valve body. A label indicates 'TCC PWM Solenoid must be installed even though it's not used!'

Pan Gasket Information

Note: This is an OE molded pan gasket that is required for modulator clearance. Your transmission may not have this gasket; it is not supplied in the kit. GM Part #: 8677743.

Step 1: Spring Replacement in Retainers

Carefully pry the lower retainer out of the springs. Using side cutters, grab each spring close to the upper retainer, twist, and pull simultaneously to remove them. Install the furnished springs into the old retainers.

Diagram Description: Illustrations show 'Upper Retainer' with '16 Springs', 'Lower Retainer', and 'Direct Clutch Drum'.

Step 2: Install Thicker Snap Ring

Install the new, thicker snap ring. This is the final snap ring to be installed in the case. It helps prevent wear on the lugs, reducing lug blowout.

Diagram Description: An image shows the 'Pump Body' and an 'Intermediate Snap Ring'.

Step 3: Enlarge Hole for Seal Prevention

To prevent front seal blowout, enlarge the indicated hole to 1/4 inch (9/32 inch).

Diagram Description: An image shows the 'Pump Stator' with an 'X' mark indicating the hole to be enlarged.

Step 4: Drill Hole in Pump Stator

Under the "X" mark, drill a 3/64 inch (0.042-0.055 inch) hole through the side of the wall in the direction of the arrow.

Non-Lockup Converter Usage

When using a NON-lockup converter, order TransGo P/N 48-CCV. This part provides corrected oil flow into the converter, keeping it full for better cooling.

4L80E-HTRK: Hi-Temp Ring & Endplay Upgrade

Corrects/Prevents/Reduces:

• No Lockup and 4th gear hot (Codes 68, 39, 85)
• Hard shifts and no 4th gear
• Direct Clutch Slippage
• Prevents Metal Particles by Separating Shafts
• Hot Idle Forward Clutch Slip, Aborts LU & 4th
• Reverse Delay - Bindup in reverse when hot

Image Description: A box labeled 'GIL YOUNGER Transmission Parts With An "ENGINEERING DIFFERENCE"' is shown with various seals and rings.

48-CCV: Converts Lock-up Pump to Non-Lockup Converter

This kit is for converters WITHOUT a converter clutch only.

Image Description: A box labeled 'TRANSGO An Engineering Difference' is shown with a diagram of a part and text 'CORRECTS, PREVENTS, REDUCES AND UPGRADES You'll just Love it'.

Step 1: Drill and Install Fitting

Drill an 11/32 inch hole at the black dot location. Ensure the hole is positioned in front of the bolt boss as shown in the picture. Tap the hole from this side with a 1/8 inch NP tap. Install the fitting into the case using sealer.

Diagram Description: An image shows the valve body with a black dot indicating drilling location. A label points to 'Bolt Boss'.

Step 2: Install Purple Spring

Install the PURPLE pressure regulator spring. The PURPLE spring MUST be used when installing the vacuum modulator.

Common Complaints: No Lockup or 4th gear when hot with codes 68, 39, or 85 are common. Often caused by leaking factory type rings that are sensitive to heat. For a lasting fix, order the 4L80E-HTRK, a Hi-Temp, Low Shrink ring kit.

Step 3: Adjust Pin Length

For normal use, shorten the pin to 1.325 inches. If shifts are too firm, shorten the pin further, but do not use a pin shorter than 1.285 inches. Grind as necessary. Use a pin length of 1.365 inches for Hi-stall converter use.

Diagram Description: Measurements are shown: 1.365, 1.325, 1.300, 1.285 inches.

Step 4: Install Modulator Components

Install the bushing, valve, pin, and modulator. Then, install the long plain spring inside the hose and secure with two Zip ties.

Diagram Description: An illustration shows the 'Modulator' components: 'Pin', 'Flat', 'Valve', 'Bushing', 'Bracket', and 'Zip Tie'.

Step 5: Install Bracket

Remove two bolts and install the bracket loosely. Push the modulator and the bracket inboard, then tighten the bolts.

Step 6: Resistor Installation

If the transmission has a functional electrical system, discard the Pressure Control Solenoid and install the included resistor.

Step 1: Route Brake Line

Using 3/16 inch brake line (not provided), route the line down to the modulator case fitting. Ensure enough line is used to comfortably reach within 2 inches of both the vacuum brake booster Tee location (Step 2) and the case vacuum fitting. After determining the correct length, cut the brake line and swedge both ends to prevent vacuum hoses from slipping off. Secure lines and hoses with Zip-ties.

Diagram Description: An illustration shows a Tee fitting connected to a vacuum hose and brake line. A note states: 'Supercharged or Turbo'd engines require bypass here between Tee and 3/16 brake line leading down to trans. Always zip-tie lines to prevent them from slipping off.'

Step 2: Install Tee into Hose

Cut the power brake hose and insert the Tee into the hose. Install zip-ties to prevent vacuum leaks.

Step 3: Connect Vacuum Hose

Install a short piece of vacuum hose between the case fitting and the brake line. Ensure the rubber vacuum line is as straight as possible to prevent kinking. Zip-tie the hose to the line and fitting as shown.