Advance Adapters 50-0401 - Manual (Page 2)

GM 2WD 32T 4L80 AUTOMATIC TO
JEEP DANA 300 TRANSFER CASE
ADVANCE ADAPTERS, INC. P/N: 50-0401
P. O. Box 247, 4320 Aerotech Center Way New Item: (01/99)
Paso Robles, CA 93447 PAGE: 2 OF 3
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 01-14-99
SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand the modifications or changes that will be required to complete
your conversion, we strongly recommend that you contact our sales department for more information. This Instruction Sheet is only to be used for the assembly
of Advance Adapter components. We recommend that a service manual pertaining to your vehicle be obtained for specific torque vales, wiring diagrams and
other related equipment. These manuals are normally available at automotive dealerships and parts stores.
GM 4L80 4 SPEED AUTOMATIC
The GM 4L80 has a case length of 26", 17 bolts for holding the oil pan in position. The rear side of the transmission case
will have a hex shaped bolt pattern that uses 6 bolts. There are several various lengths of output shafts that the transmission
has been equipped with. You will need the 6-1/2" slip yoke output shaft GM# 8661596 (1991 to 1996), or GM# 24204289
(1997-1998). The speedometer pickup is normally located in the tailhousing, but when adapting it to the transfer case, the
location will change to the backside of the transfer case. The rear transmission support will now be located on the new
adapter housing or, in some cases, on the transfer case.
When installing the new transfer case adapter, make sure that the new input gear and the output shaft do not bottom out.
We have found on occasion that the output shaft and transfer case input sleeve may bottom out if the shaft was not cut
to the proper length.
DO NO FORCE THE NEW TAILHOUSING ONTO THE TRANSMISSION. If assistance
is needed, please feel free to call the number listed above.
When assembling the adapter housing to the transmission case, we have provided you with a new gasket to prevent fluid
leakage. This gasket is a stock GM item that is used on all 4L80 installations. The seal in the Dana 300 bearing retainer
will prevent fluid from mixing between the transmission and transfer case. A new seal has been provide and should be
installed with the open side towards the automatic transmission. We have also included a new sealed bearing that will
replace the original Dana 300 bearing. This new sealed bearing will give added protection.
All installations will require the use of a transmission cooler. The cooler can be either installed in the radiator or a remote
location is acceptable. The transmission shift control can either be a Hurst floor mounted type shifter or sometimes the
existing column shift can be modified on certain applications.