Build thread for rebuilding the 6L80

[Posidon42]

My inward facing clutches were cupped too. Of course, the clutch material was completely missing off two of the clutches. The manufacturer spec says they need 0.045 to 0.055 of clearance with the stock clutches and the wave plate. Century said without the wave plate and with the aftermarket clutches you need almost double that clearance to have the clutches completely disengage. That's why I sent mine back for machining. Tom, Ron, (something like that) is the trans builder at Century. He said when they rebuild a 6L80, they pretty much automatically cut 0.050 off the 3-5-R pressure plate. Then they reinstall it for final measurement.

[Posidon42]

004 (Large).JPG - High Res - Here is how I measured the clutch clearance for mine.
008 (Large).JPG - High Res - 3-5-R component assembly from the ATSG manual
007 (Large).JPG - High Res - Alto assembly instructions

[TimC]

Thanks for the info. Did Tom/Ron say why the clutches were cupped? Mine have only been in there for a month.

[GT Drew]

Heat is what "cones" the stock clutch plates. The higher quality replacements are made with better, more stable steel that resists the warpage from heat.

[TimC]

These are the upgraded clutches. My trans builder wants to see the clutches and drum tomorrow. Hopefully he has some ideas

[TimC]

I was able to get the clutches warrantied but I'm pretty much on my own to get this thing to hold the power.

I ordered the new pump cover kit from the dealer yesterday. Part number 24248573. It is supposed to be better than the first design and comes with better seal rings to make sure the fluid gets to the clutches instead of leaking out. Queensland automatics has a replacement spring for the main pressure regulator and pump return spring. I'm going to call them tomorrow (Monday in AU) and see about those springs.

[gr8lover]

I was able to get the clutches warrantied but I'm pretty much on my own to get this thing to hold the power.

I ordered the new pump cover kit from the dealer yesterday. Part number 24248573. It is supposed to be better than the first design and comes with better seal rings to make sure the fluid gets to the clutches instead of leaking out. Queensland automatics has a replacement spring for the main pressure regulator and pump return spring. I'm going to call them tomorrow (Monday in AU) and see about those springs.

before you install.... I would be interested in exactly what they give you... just to make sure its correct... I know some kits that are wrong... include pics and descriptions before installing... I can help to confirm it is correct or not....

[TimC]

What would be wrong? The clutches look right to me. I checked clearance and it's only .065 or so. I'm going to check it again tomorrow and cut that pressure plate to get to the .085-.095 alto recommends.

[gr8lover]

What would be wrong? The clutches look right to me. I checked clearance and it's only .065 or so. I'm going to check it again tomorrow and cut that pressure plate to get to the .085-.095 alto recommends.

I mean for the pump kit..... many times they dont understand exactly which seals and orings go onto the pump stator shaft.... many times they mix the wrong stator and orings/ring seals... Service and the dealers have made mistakes on this... heck for mine they gave me the wrong ring seals..... they appear correct but will not work correctly on the shaft I got...

the new design has deeper grooves in the stator shaft and include orings that go under the new designed ring seals(original design didnt include orings... only ring seals..)... the new design also requires different ring seals than the first design even though the old ones appear to fit the will not work correctly. just hate to see someone get wrong parts...

[Sephiroth]

WOW.


I would have never dreamed of doing this, but now that you've posted pictures, it looks so simple.

<3