Build thread for rebuilding the 6L80

[hartigan85]

Yes, this is the first rebuild I have done. However, I am a mechanical engineer and feel pretty good about the process. As for the tools, here is what I ordered:

6L80 tech manual

Minimum special tools you'll need:
6L80 valve body bolt socket (you can make one with a 4l60 bell housing bolt, double-nutted) - bought mine directly from Snap-on, part # FLEPL100
J 45126 Snap ring pliers & DT 47773 adaptor kit (to remove huge center support to case retaining snap ring)
DT 47781 3-5-R drum installer (not totally required, but makes drum install very-very much easier!)

Thanks dude I will have to write those down for when I do mine. If you don't mind me asking, how much was the rebuild kit from century? I looked on their website and it only has the mail in transmission price.

[Posidon42]

Made some good progress today. Rebuilt the 4-5-6 drum about 3 times until I realized I was reading something wrong in the instructions. I also am going to have to send that pressure plate back in for machining. They want about 0.085-0.095 clearance and I only have 0.076.

As for why I am rebuilding it, pretty much all of the clutches are extremely burned. The 3-5-R clutches are the worst, as expected. Some of the steels were REALLY warped and the bottom plate looked like it had been spot welded.

Rebuilding is at a halt as either I am doing something wrong, or I was sent the wrong parts for the 1-4 clutch pack. They just don't fit. Will post some more pics in a few.

[Posidon42]

trans20110918131839.jpg - taking apart the 4-5-6 clutch. Pretty toasted
trans20110918131934.jpg
trans20110918131945.jpg
trans20110918161341.jpg- my ghetto clearance gauge. Not pretty, but it worked well after putting it back together for the third time...
trans20110918164940.jpg - Starting on the 1-4 and 3-5-R clutch assembly
trans20110918165022.jpg - Taking out the snap ring
trans20110918165224.jpg - Removing the pressure plate
trans20110918165300.jpg - these were REALLY bad. Some of the steels were physically warped and the clutch material was completely missing on some of them. I am 99% sure these are the same clutches I am putting back in. They have the same cross hatched pattern on them as the replacements. Hopefully they hold up better.
trans20110918165321.jpg - warped steel
trans20110918165327.jpg - another warped steel

[Posidon42]

trans20110918165345.jpg - looks like spot welds on that steel plate
trans20110918165403.jpg - close up view
trans20110918165442.jpg - Taking out the 'cage' for the 1-4 clutches
trans20110918165715.jpg - removing another snap ring
trans20110918165909.jpg - More burned up clutches
trans20110918170303.jpg - Hrm... this doesn't quite fit... (edit) That's because that went with the 2-6 clutch pack that I haven't rebuilt yet.

So I get to buy more parts. The kit doesn't normally include the 1-4 clutches as they are rarely damaged. However, these need to be replaced as well and I am looking forward to another week of downtime...

[travis gore]

thanks for sharing the photos and process...god luck and I hope all turns out well for you

[Posidon42]

When I am done, I will make a writeup that will document more of the process and tell about some of the lessons learned. Hopefully make it more sticky worthy

[Posidon42]

Rebuilding is at a halt as either I am doing something wrong, or I was sent the wrong parts for the 1-4 clutch pack. They just don't fit. Will post some more pics in a few.

I did something wrong. I was trying to fit the 2-6 clutches where the 1-4 go. Unfortunately, the 1-4 weren't supposed to be replaced as part of this kit. At least I can still rebuild the 3-5-R part to measure the clutch clearance, but I have to order another set of clutches Sucks because I have a Cub Scout overnight next weekend and then I am out of town the following week for a business trip. Looks like it is going to be October before she is up and running.

[1baddbird]

Did you ever change the shift time via hp tuners? also the torque management may be part of your problem. slow shift times will kill clutches.

[Posidon42]

2-6 clutch reassembled. The clutches actually didn't look all that bad. The steels were a little blue, but I could still read the Raybestos logo and the part number on the clutches. Replaced them anyway though. An additional curiosity was that the old parts and the new parts were exactly the same part number, but the one ones only came with 5 sets, when the old ones had 6 squeezed in there. It couldn't have been good though, as I don't have enough clearance with just the 5 sets of clutches/steels. I need it to have between 0.045 and 0.055. I only have 0.038 Looks like all of the pressure plates are going back for machining. Going to call Century in the morning to make sure I measured the 3-5-R clutch correctly before I send it in.

[Posidon42]

Did you ever change the shift time via hp tuners? also the torque management may be part of your problem. slow shift times will kill clutches.

Nope, I only drove it 3 times before rebuilding it. I just bought this car a couple weeks ago but knew it had trans problems when I bought it. I was hoping to get it to live through the Fall before taking this on, but it wouldn't old ANY power in 3rd at all. So while I still have two other cars, (anyone wanna buy an 07 Odyssey?) I am taking my time to get this done. It is actually a lot of fun, just wish I didn't have to send parts back and forth for machining.

As for the tune, Mike @ Century is going to help me with that once I get it back in the car. Probably going to hit up the new HPT trans settings thread and grab something from there just to get it up and running.

The torque management was one of several factors which led up to this. This is going to be my DD, so I have no plans on pushing it hard.