2010 L99/6L80E swap into 95 C1500 Silverado

[doubleds19666]

Next was the R4 A/C compressor install using LSbrackets made for such a thing. Installing the old compressor was done to keep the functionality of the interior. I did ponder using the new one that came with the donor motor, but alas...

[doubleds19666]

Up next, electric spaghetti! I modified the truck harness before this point to remove all the unnecessary circuits. No small task, but my profession is as an jet engine test cell technician with a background of fixing AH-64D/E Apache Attack helicopters helps.

[doubleds19666]

I used the schematics from the 2010 Camaro (http://www.revbase.com/BBBMotor/Wd) as the basis for modifying the harnesses. I probably went a little over kill on how many fuses and relays I used, but I wanted the poor fella down the road that might have the pleasure of owning this truck to not give up on fixing it if a problem arises. So, the plan was for 15 fuses and 7 relays as the brains of the operation to support the new harness mod. I am happy to report that no electrons were killed in the making of this harness mod.

Also, want to throw a big thank you out to http://lt1swap.com/wiringharness.htm

Not the end all for what I needed, but he helped push me in the right direction until I found the schematic database link at the top.

I will attach a swap spreadsheet I used throughout the process at the end of the thread. It has all the wiring info and part numbers used for the swap.

[doubleds19666]

There were a couple more things to iron out before applying power and attempting to start it. The gas pedal assembly is drive by wire. Had to make a mount for it to be in the correct position to drive and have WOT.

[doubleds19666]

Transmission cooler lines finally finished along with a passenger side shot of the cooling fans. A 2008 Hummer H2 shifter cable bracket and lever were installed to work the stock cable on the column for grinding gears. A Denny's driveshaft with a slip yoke was installed. It also got a new 1350 Pinion Yoke and seal for good measure.

[doubleds19666]

Had to install custom made power steering lines after many attempts to reuse the factory hoses. Had to take the pulley back off to get the fitting started and tightened.

[doubleds19666]

Next up was figuring what air cleaner to use. Ended up buying a Spectre unit for the 2010 Camaro SS with the L99 and made a bracket out of 4" exhaust clamp saddles and some metal bar stock from the hardware store.

[doubleds19666]

Here are some pics of the electrical panel and the process of building it. I made the harness too short the first time, so had to splice in extra wire to fix it. Rookie mistake, measure twice...cut once I used garage door railing as the mounting structure on the inner fender. Plexiglas is under the fuses and relays to help with short circuit protection.

[doubleds19666]

Had to figure out how to get the neutral safety switch, the backup lamp switch, and the gear indicator switch to work with the 6L80E. The top picture is how it all fits in relation to size if using OEM stuff. The shaft on the shift lever on the transmission isn't long enough for the old 4L60E stuff so...

[doubleds19666]

The answer:

GSS-2000 from Dakota Digital with lots of mods...

Had to modify the brackets to mount it.

Had to make an interface circuit between the "decoder" from the RVDT on the transmission and the logic circuit for the gear lamp indicator in the truck.

I will post all my schematic support at the end of the thread, by the way, we are almost there!

[doubleds19666]

Next up is the ABS speed signal for the rear tires. Used to be a 40 tooth reluctor ring and pickup in the tailhousing of the 4L60E. Not so much on the 6L80E, much less that it talks over CANbus...

Jagsthatrun 40 tooth reluctor wheel kit to the rescue

I had to over size drill the holes to line it up on the pinion yoke. The mounting bracket for the sensor had a hole drilled to position it correctly on the housing and a plate welded to the bottom to provide a spacer and keep it level where it mounts. I still need to take a final photo of that for you all...

I also put a picture of the resistor mod I did to the temp gauge on the back of the instrument panel. It is 47 ohms, which is perfect for idle while sitting still, but 30 degrees too low for driving down the road. As I mentioned earlier, the 98 Camaro/Firebird LS1 ECT sensor will be going in next to finish the project off.

[doubleds19666]

I used HPtuners to get it running, but still need to do a little gear manipulation for it to feel right while downshifting. Tried for 2 days without getting fuel to start it before I figured out starter control had to be disabled in the tune.

I will upload some video to youtube and post the links here when done.

Here are the files I promised during the thread to share. If you have any questions on the information I will help as much as possible.

[doubleds19666]

More of the files for the swap...

[doubleds19666]

Interface schematic, and the diagram for the 4 wires from the truck and the logic for pulling the GSS-2000 to ground(sink) for the circuit.

[doubleds19666]

YouTube links:

5.7L before pulling for the swap
https://www.youtube.com/watch?v=QW_eXWr7ues

Open headers in the shop after the swap
https://www.youtube.com/watch?v=LoDR37qwzlM

Maiden voyage to hook the exhaust back up
https://www.youtube.com/watch?v=icAH20Fd-Uo

Enjoy

[dayj1]

Great job with documenting what you did. I found your interface for the gear indicator especially interesting. Nice work!

[doubleds19666]

Thank you for the kind words dayj1. I really wanted to re-use the switch from the 4L60E, but other than getting a longer shaft machined for the 6L80E or using some type of gearing or chain drive the GSS-2000 was the way to go.

[68c10airstream]

Nice truck to transform and nice job. Be ready for that 5,000 rpm stock tach to spin way past that lame 5,000 limit. Save your old 95 distributor for the guys here with tbi and starting, etc troubles, maybe save your ecm and egr valve.

[doubleds19666]

68c10airstream,

I am still using the ecm for my gauges and abs system along with ignition control, DRAC, and such. I still have all the parts from the swap, need to clean them up to store and or sell it all. It had the bigger aftermarket Holley TBI unit, long tube headers, etc. for what little bit of power gains I could get while still running the old 5.7L.

[dec010974]

Thanks for sharing. I'm inclined to do a swap for my 1998, Chevy, 2 door Tahoe, a L92. I definitely want to use my 4l60e. It's makes things easier for me. Thanks for sharing.

[Hart_Rod]

Very well done! If you do a search on HPTuners for "bluecat transmission". There's a tool on there that you can download that really helps with fine tuning the A4's and A6 transmission. Do you plan on installing TUTD?

[faribran]

Thank you for the wiring link. Excellent
Btw. Your work is impressive

[doubleds19666]

Dec010974,

If I can do this swap you can certainly handle the L92 swap, especially if you keep the 4L60. The hardest part of mine was trying to tap into the existing parts and gauges with the CANbus comms the donor uses. Dakota Digital makes some really nice things to help this happen.

[doubleds19666]

Hart_Rod,

Like the username. I should have chosen not to use my email address for mine since I no longer have a 66 C10, nor to end the confusion on the doubleds part. Which is an old nickname from dart league, I could throw doubles all night long and the ds is my initials. Sounds more like a boob joke, but alas, I digress.

I will check out the useful info you provided for the transmission tuning. I plan on upgrading to a locker rear end after the first of the year. Followed shortly by adding cruise control. Then I might try to tackle the TUTD shifting, but I have to make money to spend it...

Thanks for the kind words on the build.

[doubleds19666]

Faribran,

Thank you for the kudos. It took twice as long as I planned, but I managed to get it on the road in 16 weeks while working 50 hours a week at my job.