4L80E into 01-06 Yukon XL Denali
03-19-2024, 02:16 PM
#1
4L80E into 01-06 Yukon XL Denali
Hello all,
I'm looking to build a nice family hauler and tow rig out of a 01-06 Yukon XL Denali. Been in the LS world for about a decade now and intimately familiar with the engines, so the 6.0 is a no-brainer for me. Haven't yet purchased a truck, so I'm still in the process of determining which year is more advantageous.
Anyone swapped a 4L80E into one of these and kept the original transfer case and AWD? Plans are a small turbo long term, so no way I want to run any kind of 60E/65E. I'm sure some folks have had good luck with their built 60E but I am not interested in going down that path at all. Apparently the issue is with adapting a 4WD 4L80E to the transfer case in the Denali.
Can the transfer case in the Denali be reused, and what kind of adapter is required to make it work? I see someone used to make gear adapters for this but no longer does.
I'm looking to build a nice family hauler and tow rig out of a 01-06 Yukon XL Denali. Been in the LS world for about a decade now and intimately familiar with the engines, so the 6.0 is a no-brainer for me. Haven't yet purchased a truck, so I'm still in the process of determining which year is more advantageous.
Anyone swapped a 4L80E into one of these and kept the original transfer case and AWD? Plans are a small turbo long term, so no way I want to run any kind of 60E/65E. I'm sure some folks have had good luck with their built 60E but I am not interested in going down that path at all. Apparently the issue is with adapting a 4WD 4L80E to the transfer case in the Denali.
Can the transfer case in the Denali be reused, and what kind of adapter is required to make it work? I see someone used to make gear adapters for this but no longer does.
03-20-2024, 07:28 AM
#2
AMP Drivetrain still shows/lists a 32 spline input shaft for np149 transfer cases
If that's still available, then you should be able to use a 4wd 4l80e with 4l80e t case adapter flange...swap the transfer case input shaft...bolt it all up and hit the road
Well...hit the road after you do all the other necessary swap items like trans mount, cooler lines, flexplate, converter, wiring/tuning, driveshafts, shifter, etc
If that's still available, then you should be able to use a 4wd 4l80e with 4l80e t case adapter flange...swap the transfer case input shaft...bolt it all up and hit the road
Well...hit the road after you do all the other necessary swap items like trans mount, cooler lines, flexplate, converter, wiring/tuning, driveshafts, shifter, etc
03-20-2024, 07:42 AM
#3
I should elaborate
01-02 Yukon Denali and Cadillac Escalade got the NP149
03-06 got a Borg Warner 4481
The 149 is purely mechanical AWD achieved via a viscous coupler
The 4481 is an open differential essentially in a t case and it uses the ABS module to control the brakes to split tq wherever the ecu determines it wants it.
The 4481 is not desireable at all IMO
You can swap a 149 into the later years but it's a bit of work
You'll need to lock the front axle disconnect or better yet swap in an early diff. If you want you can buy just the passenger side longer 1 piece axle and housing without the disconnect.
Then you'll need to program the BCM with a 2wd program so that the ABS doesn't freak out and cause issues with your brakes.
Alternatively you could just eliminate ABS altogether but I wouldn't recommend that.
Another option would be to a nice Tahoe or Non-Denali Yukon that has an option package you like. Those should come with NP246 transfer case. You can also swap the input shaft on those to a 32 spline. Then all the same steps as above for the 80e swap.
NP246 is a selectable transfer case so you can do 2wd burnouts when desired. Get *slightly* better highway mileage in 2wd. Then have locked 4x4 when it is desired. Bonus points for a low range available.
Lots of options for you to consider.
Easiest of them, if you're stuck with wanting a denali, is to find an 01 or 02, swap the t case input shaft, use the 4l80e t case adapter, and call it a day.
01-02 Yukon Denali and Cadillac Escalade got the NP149
03-06 got a Borg Warner 4481
The 149 is purely mechanical AWD achieved via a viscous coupler
The 4481 is an open differential essentially in a t case and it uses the ABS module to control the brakes to split tq wherever the ecu determines it wants it.
The 4481 is not desireable at all IMO
You can swap a 149 into the later years but it's a bit of work
You'll need to lock the front axle disconnect or better yet swap in an early diff. If you want you can buy just the passenger side longer 1 piece axle and housing without the disconnect.
Then you'll need to program the BCM with a 2wd program so that the ABS doesn't freak out and cause issues with your brakes.
Alternatively you could just eliminate ABS altogether but I wouldn't recommend that.
Another option would be to a nice Tahoe or Non-Denali Yukon that has an option package you like. Those should come with NP246 transfer case. You can also swap the input shaft on those to a 32 spline. Then all the same steps as above for the 80e swap.
NP246 is a selectable transfer case so you can do 2wd burnouts when desired. Get *slightly* better highway mileage in 2wd. Then have locked 4x4 when it is desired. Bonus points for a low range available.
Lots of options for you to consider.
Easiest of them, if you're stuck with wanting a denali, is to find an 01 or 02, swap the t case input shaft, use the 4l80e t case adapter, and call it a day.
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strutaeng (03-20-2024)
03-20-2024, 02:27 PM
#4
The 03-06 yukon denali uses the bw4481 tcase and it is like an open differential, and relies on the braking system to slow the slipping wheels down, as mentioned above. On the highway and even mild trails, it works great!! Very good towing too. The gmt900 awd suvs use the same setup, but a bw4485 tcase in most. For performance, i would greatly lean toward the nv149, but highway, the computer running the awd works great for me.
Most, not all, agree that the 03-06 trucks and suvs have advantages that out weigh the 99-02 (or 01 and 02 denali), but look that up and decide on your own, as I don’t mean to offend or start any arguments.
To the question, the 03-06 use the bw4481, and it has a speed sensor i believe in the tail housing. A bw4485 from a 6l80e truck will bolt to the 4l80e, but has no sensor. One build has used the front of the bw4485 and the tail of the bw4481 and he got his working.
I personally used a 2wd 4l80e, removed the tail cover, use my shaft to fit the tcase, and am using a complete bw4485; I use the 2wd 4l80e rear speed sensor instead of the one that used to be on my tcase, since the 4x4/awd 4l80e has no reluctor ring in the tail shaft. Many wont prefer my way, but I couldn't find a 4x4 4l80e, and I also didn't care to tear into a tcase at the time.
I also have a 4l80e swapped 2004 tahoe, and I found a np246 from a suburban 2500 to swap into it instead of changing input shafts: if you do that, just make sure you specify the 01-02, or the 03-06, as they are different.
Most, not all, agree that the 03-06 trucks and suvs have advantages that out weigh the 99-02 (or 01 and 02 denali), but look that up and decide on your own, as I don’t mean to offend or start any arguments.
To the question, the 03-06 use the bw4481, and it has a speed sensor i believe in the tail housing. A bw4485 from a 6l80e truck will bolt to the 4l80e, but has no sensor. One build has used the front of the bw4485 and the tail of the bw4481 and he got his working.
I personally used a 2wd 4l80e, removed the tail cover, use my shaft to fit the tcase, and am using a complete bw4485; I use the 2wd 4l80e rear speed sensor instead of the one that used to be on my tcase, since the 4x4/awd 4l80e has no reluctor ring in the tail shaft. Many wont prefer my way, but I couldn't find a 4x4 4l80e, and I also didn't care to tear into a tcase at the time.
I also have a 4l80e swapped 2004 tahoe, and I found a np246 from a suburban 2500 to swap into it instead of changing input shafts: if you do that, just make sure you specify the 01-02, or the 03-06, as they are different.
Last edited by jonnyboy; 03-20-2024 at 09:14 PM. Reason: Typo
03-23-2024, 12:44 PM
#5
and if you're really lucky, you can find a 4L85 from an 8.1 suburban/avalanche... the swap considerations are the same swap, but it but has a stronger planetary & other bits that a 65 has over a 60.
also, some 4.11 or 4.30 gears would really help your converter with the weight of these SUVs + the gearing of the 80/85 (assuming you're keeping stock-height tires).
also, some 4.11 or 4.30 gears would really help your converter with the weight of these SUVs + the gearing of the 80/85 (assuming you're keeping stock-height tires).
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