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I replaced the oil cooler lines, AC Delco from rock Auto. Almost a perfect fit. I had to make a new clamp on the end at the motor. The bends in the new lines made the old one short. Been driving the truck a lot. I have been adjusting the shift points and I am close to getting it dialed in...

My controller only asked tire size and gear ratio. The first controller they sent me had an EFI program and not a trans program. The second one had a trans controller program but did not work. The took the second one back and reprogramed it and sent it back and it was still bad. One of the...

Got the truck on the road. The parking brake cable works well, The transfer case brake it self rattles a little but does hold ok for a parking brake. Got the transmission adjusted and it shifts well. At 65 MPH, the speedo reads 54 and the rpms are right on 1800. It has a little wobble to it...

Got the Transmission installed. Had to pull it one more time to fix leak between the magnum and 205. I did not get one of the bolt holes sealed good. Ran the truck a few miles tonight to get all the fluids warm. At this time I have no leaks that I can find. I put some fresh cardboard under it...

4l80e running good Got the trans installed and a little driving in for the first time in about two years. Had to take a lot of long breaks from the project due to work. I do not have a trans lift but have become very good at installing just using a floor jack. The trans, magnum box, 205...

I got my tranny back from being rebuilt for the second time. The POS tranny controller from TCI over pressured the tranny and messed up the electrical plug connection and made it leak really bad, it also blew some internal O-rings and seals. They had to take it apart and put it back together...

the only difference is the rear output shaft and housing adapter between two wheel and 4 wheel. The housing addapter bolts on to the exterior and can be changed without rebuilding the trans. to change the output shaft, you have to rebuild the trans. I had a two wheel drive unit and bought the...

I do not beleive there is a stock controler for the 4l80e and 6.2 becasue I do not think they were ever available in production vehicle, I do not beleive the 6.2 was ever used with a 4l80e since the 6.2 was replaced in I think 92 with the 6.5 and the first of the 4l80e was in 92 also. I could...

It looks like the third time is the charm with TCI. I finally got a chance to install the controler today and it appears to work. Due to my driveshaft issue I could only get it up to about 40 mph and it shifted fine from first, second and third. I did not want to go any faster and risk the...

The cost is roughly $2000 for 4l80e installed on stock suspension with standard 208 slip yoke t-case. Trans core and rebuild cost me $900 torque converter $200 Trans computer $600 Drive shaft rebuild $200. I however have a 5 inch lift so slip yoke does not work. I have installed the 208 slip...

talked with TCI again today and discussed the new issues. From what I was able to tell them they informed me that they beleive they sent me a handheld programed with the fuel injection program and not the trans controler program. I was not able to talk to them until after 3pm today so now we...

Got the controler back today. The current history is: TCI received the controler on December 14 and notified me on december 17 that nothing was wrong with it. It was stuck in program mode when I had it. The hand held had a blemished screen and yes they were replacing it as soon as i gave them...

At this time I am not saying it is a bad unit because I got a bad one out of the box. I will say the people at TCI need some talking to and maybe a few lashings would help. I hope to have the unit back by the end of this week so I can re-install it and then see how well it opperates. Once i...

what did you use to resize the bearing yourself. I am looking at taking it to a machine shop for this because I don't want to screw it up. I have been busy with other smaller items because I am still waiting on my trans controler from TCI. I am very unhappy with TCI. I sent the unit to them...

I mailed my non working 'TCI fast TCU controler' back to the company today to have them either fix it or give me a new one, they seemed to be decent folks on the phone, It will be at least a week before I have any info on what they are going to do to fix it. I also ordered my Magnum box from...

OD dave, I should be able to just take the fixed flat yoke off of the front of the 208 shaft and put it on the shaft of the 205 if the 208 has 32 spline. I do not have to do anything with the shaft or seal, do I?

My 205 currently has the front shaft upgraded to the 32 spline large output with 1350 yokes. I am looking for the fixed flanges for it now (if you know of a good source let me know) I am going to keep the front drive shaft from the 1008 parts truck that I have to get rebuilt for the rear. I...

The details on my 14 bolt axle install are: I cut the perches off and moved them to fit the 1009. I also cut off the shock mounts and rewelded new tabs on the tops of the tubes. My upper shock mount is still outboard, some day this may change but it is not necessary (mufflers have to be moved...

I am going to go ahead and get my 205 tcase finished and installed before reworking the drive shaft. I compared the origional 1009 drive shaft with the re-worked 1008 drive shaft and they have almost the same max angle. With the lift and moving the tcase back neither slip joint style shaft...

sorry, i ment drive shafts. the front yoke on my 1008 had the smaller yoke. the rear was larger. you do have to move the spring perches on the rear axle to put the 14 bolt on a 1009