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towing/hauling with 4L80E & fluid type/Cooling system ?'s

let me give some of your questions a shot and would appreciate any feedback-- retired service manager

(2)
Now for Fluid type is this better off on Dino oil or run with a high end synthetic Fluid ?
Remember than many "Synthetic" or "Fully Synthetic" is hydrocracked Dino OIl - lots of BS to wade through
Absolutely Best fluid is Allison Transend TES 295 and best Tansend style but better is CITGO QuatraSyn
why? TES295 is a Group III type synthetic mostly wheras QuatraSyn is a Group IV (PAO) V mostly Synthetic
why "mostly" some Group III is needed to better carry the additive package
Group IV and V base stocks are EXPENSIVE
I can't see what year you have but trans before certain numbers in 2007 took DEX III and later took Dex VI
do not use Dex VI in the earlier trans as soft parts go away
Dex III (even DEX IIII H) is obsolete- best is Certified Allison TES 389 certified or use MOPAR ATF +4 (which I like better than even DEX VI) but DEX III or DEX MERC or "MAX" change often

How often should the fluid and filter be changed in these units ?
Depends on usage low speed with Converter unlocked and big load is hardest
Transend works better when cold AND when HOT should last about forever unless plowing or similar
you can use it in your power steering-power brake unit also
any DEX III-VI, Mercon except latest and most Jap (Nissan K,J,S) etc

What type of fluid exchange would be best for these units ?
double change if old with some time between changes, change filter after second change, inspect OR
The dump, change filter then removing the cooler return line and flowing 2 quarts at a time till it comes clear gives you slightly more of a change but is a pita to do by yourself

.................................................................................................................
(3)
Now how about the cooling of these units ?
Do these Trans pan coolers work ?
IMHO not much- not enough airflow- but if you are off road a deep pan helps

The extra 1qt in volume with flow threw cooling tubes ?
or
The extra 3qts in volume with cooling fins ?
still gets hot but if you are on hills extra depth can help most trucks have a deep pan compared to cars
if you do get a aftermarket deep pan have a source of deep filters or why bother
...................................................................................................................
(4)
Now is the GM factory Cooler mounted by the Radiator the best way to go ?
or
Should and after market unit unit be used ?
there have been suggestions about a gauge
that said if you are into heavy duty use or live in very hot weather in stop and go or hills then swap out the factory add on cooler with a bigger one
I steal them off FORD trucks at pick a part- mount where they get air flow

some say get the GM cooler and bypass the Rad.
The Rad does most of the cooling at low speed
The trans can get hot without the fan coming on and the in rad cooler will still cool (and the fan will come on)
you need a gauge and a monster add on cooler
I would also NOT do it in like AK or MN
I have one vehicle with add on cooler only but have temp controlled electric fan on it

Some say get the GM cooler and run it inline with the Rad.
What is usually done I have one vehicle with inadequate radiator and not much room which has cooler before (to help the rad) and after (to cool the trans) works fine but a pita

Some say after market next size bigger than your gross GVWR inline with Rad.
use the biggest cooler you can fit- you cannot go too big
use a stacked plate cooler not a "tube and fin" of flat tubes (which look like a stacked plate sorta)

Some say next size bigger than you GVWR bypass the Rad.

Whats the best setup For the 4L80E ?
I'd add a transdapt oil filter adapter - regular big oil filter works fine
will save your radiator and cooler if the converter clutch lets go
(like it will if you run trick or type F fluid)
let me know if you are thinking of a "shift kit"
most do not really need one with this trans unless hot rodding or really hard use
 
wyrmrider: Interesting write up, however the most efficient (heat rejection) type of cooler is 'fin-plate aviation type' followed by plate cooler however the plate cooler is considered more durable when it comes to stone strikes when not using some type of screening.

I've used AMSOIL since I had lost my 1st 4L80e back in 01 but I have never compared it to any of the aforementioned products out there. I like that it flows at real low or high temps and run through the radiator into 2 additional coolers 1 with manual fan as I'm in the sub tropics generally keeping the trans temp well below 150 deg. f. on triple degree days and 25/30 deg. f. lower than that generally.

I've only changed out the AMSOIL on one occasion a long time ago using the two person method with engine running 'pouring in fresh fluid until it appears exiting the return line.' Since then no fluid changes between rebuilds and crazy amount of miles and the fluid visually looks just like the day it was installed.

I've had many claim because I run my trans so cool moisture from condensation would be a problem well I've used the refractometer many times and found this not to be the case the reason revolves around temps climbing inside converter being high enough to steam off any condensation. As I'm converting to the 12 valve Cummins I'm having a billet cover 1.0/1.2k stall speed converter built and do not know yet if the converter temps will climb constantly to temps that would allow steam off of condensation buildup.

It would be interesting to see some comparison between the AMSOIL and the other aforementioned fluids.
 
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wyrmrider: Interesting write up, however the most efficient (heat rejection) type of cooler is 'fin-plate aviation type' followed by plate cooler however the plate cooler is considered more durable when it comes to stone strikes when not using some type of screening.

I've used AMSOIL since I had lost my 1st 4L80e back in 01 but I have never compared it to any of the aforementioned products out there. I like that it flows at real low or high temps and run through the radiator into 2 additional coolers 1 with manual fan as I'm in the sub tropics generally keeping the trans temp well below 150 deg. f. on triple degree days and 25/30 deg. f. lower than that generally.

I've only changed out the AMSOIL on one occasion a long time ago using the two person method with engine running 'pouring in fresh fluid until it appears exiting the return line.' Since then no fluid changes between rebuilds and crazy amount of miles and the fluid visually looks just like the day it was installed.

I've had many claim because I run my trans so cool moisture from condensation would be a problem well I've used the refractometer many times and found this not to be the case the reason revolves around temps climbing inside converter being high enough to steam off any condensation. As I'm converting to the 12 valve Cummins I'm having a billet cover 1.0/1.2k stall speed converter built and do not know yet if the converter temps will climb constantly to temps that would allow steam off of condensation buildup.

It would be interesting to see some comparison between the AMSOIL and the other aforementioned fluids.
I like your style AMSOIL should work fine
how did you plumb the coolers?
In tests we did for Chrysler - which started out with 5/16 line then 3/8 we found that by going to 1/2 inch with half inch in and out coolers dropped the backpressure measured at trans out by 45 lbs each line was worth 15 lbs and the cooler was 15 lbs
Chrysler then went to 1/2 inch line on the Diesels put a gauge on yours and see what you come up with
IDK what AMSOIL is composed of (what kind of synthetic), or Redline
I do know that any synthetic will out perform DEX III vintage specs and a group IV-V based synthetic will out perform a Group III
Mopar went from a 30,000mile "life" to a 100K "life changing from +3 to + 4 "life" being whatever equivalent test they used
also those that say that DEX VI is just a minor upgrade from DEX III do not know what they are talking about
DEX VI is much better- but not for early trans and Allison Spec is much better than DEX VI
There must be a fleet of garbage trucks somewhere that has done the comparison with AMSOIL but IDK of it
There are many tests of Allison Spec fluid in HD use
 
I like your style AMSOIL should work fine
how did you plumb the coolers?
In tests we did for Chrysler - which started out with 5/16 line then 3/8 we found that by going to 1/2 inch with half inch in and out coolers dropped the backpressure measured at trans out by 45 lbs each line was worth 15 lbs and the cooler was 15 lbs
Chrysler then went to 1/2 inch line on the Diesels put a gauge on yours and see what you come up with
IDK what AMSOIL is composed of (what kind of synthetic), or Redline
I do know that any synthetic will out perform DEX III vintage specs and a group IV-V based synthetic will out perform a Group III
Mopar went from a 30,000mile "life" to a 100K "life changing from +3 to + 4 "life" being whatever equivalent test they used
also those that say that DEX VI is just a minor upgrade from DEX III do not know what they are talking about
DEX VI is much better- but not for early trans and Allison Spec is much better than DEX VI
There must be a fleet of garbage trucks somewhere that has done the comparison with AMSOIL but IDK of it
There are many tests of Allison Spec fluid in HD use
I stayed @ 3/8" because of the fluid in/out size on my 4L80e. I know @ 1/2" things slow down thus cool down better but the trans fluid in/out should also match IMO.
 
Flow really ok with 3/8 it's the bends that get you In and out do not need to match
we tested with 3/8 in and half out and half in and 3/8 out -dropped about 15 lbs backpressure either way
chevy bends seem to have more radius than 90's era dodge- it was on the list of suggestions for them to fix
thanks for the feedback
 
GM and DODGE used cooler flow for different things as well. In a DODGE the cooler flow was actually used to supply the trans for the valve body and such. GM tends to feed the cooler circuit with oil that the pressure refulator dumps, and then uses the cooler flow for lubrication. This way apply pressure for the clutches is always on hand and theres always flow through the cooler whereas DODGE only has cooler flow when not in park.
 
On the early Dodge OD trans like the 518 the return lube flow from the cooler goes through the case (tailshaft) into a bushing that feeds the center of the output shaft which is the lube to the thrust washers in the OD and other things.
The early OD planetaries had a high helix angle thus lots of thrust and it was easy to burn up the thrust washers
Diesels had straight cut gears- no problems Later OD's had lower helix
Chrysler, in their infinite wisdom, changed the output shaft od by about .030 so early and late do not interchange
but you can put the late planetary on the early shaft and strip the od splines real soon now- other way does not fit
I have one 92 trans with well over 250K miles with the diesel gears and no problems
When we had a warranty we would rebuild with Diesel parts (extra clutches, straight cut gears, etc) instead of getting a factory Reman. Actually the Diesel Parts were less than the light duty parts.
Trans we rebuilt- well I never saw any of them again
You can also tow in OD with the Diesel Planetaries- there is not thrust and plenty of lube for the bushings
Transgo also makes a HD Spring for the OD and it's easy to dieselize the number of clutch plates
We drilled and tapped the cooler lines to the next size bigger and reamed out the oil passages as much as possible
I may have mentioned that we went to half inch cooler lines and coolers with 1/2 in and out
makes a big difference in cooler flow and helps save the thrusts.
Charysler ATF +4 is an excellent fluid, especially solves converter shudder
You can also take the complete guts out of a later trans (47) and as long as you take everything it's an easy upgrade.
On the Torqueflyte based OD cooler flow does not go back to the valve body.
That said The Torqueflye OD can be made very strong with just a few mods as can the TH400 based Chevy trans

Transgo Shift kits, even the little ones have a mod that gives lube flow in park
Gil Younger (RIP) had a patent on it but it's now expired and most everyone has a full time lube fix for the Torqueflyte
Full time lube is also good for emergency vehicles where the key is turned and the pedal is floored as the Transgo kit has an anti drainback fix. I also specify double wrap low/reverse bands for that application
cheers
 
As I have posted elsewhere:
Change the oil in the 4L80E about every 25K miles or so best time being after the hot summer. The debris screen, aka filter, isn't good enough allowing normal wear materials to circulate in the oil that will wear out the TCC lockup plunger assembly. Eventually this wear causes the weak OEM TC clutch to slip and it's rebuild time.

Oil flow: Make sure the hottest oil goes through the radiator first. This results in the lowest trans oil temps. (150-180 degrees) Dumping the hottest oil in front of the AC condenser kills AC performance and results in higher trans temps (200-220). The radiator still cools the oil vs. just a air to oil trans cooler alone (220+). I dislike the coolant leak risk, but, the trans runs too hot without the radiator cooler. The above temps are with an OEM converter. Cool running is even with the Yank stall I have. (I discovered the trans shop's cooler install plumbing mistake, putting the hottest oil in front of the condenser first with the air to oil cooler and then to the radiator, when I put the Yank in while flushing the lines. Thus I have the above numbers to post.)

Cold coolant from the cold side of the radiator does nothing to heat the trans. A brake stall will heat up the trans oil faster than the engine. High trans temps heating the coolant before the suction side of the water pump and making the trans heat go through the engine could be solved with bigger air to oil coolers. These would have to go behind the AC condenser as max useable condenser temp IMO is around 160 degrees, 300 psig, before the high side switch cuts off. Consider R134a at 380 psig is just 178 degrees. You bet 220 Degrees oil temp coming out of the trans is "normal" on a grade.
 
Oil flow: Make sure the hottest oil goes through the radiator first. This results in the lowest trans oil temps. (150-180 degrees) Dumping the hottest oil in front of the AC condenser kills AC performance and results in higher trans temps (200-220). The radiator still cools the oil vs. just a air to oil trans cooler alone (220+). I dislike the coolant leak risk, but, the trans runs too hot without the radiator cooler. The above temps are with an OEM converter. Cool running is even with the Yank stall I have. (I discovered the trans shop's cooler install plumbing mistake, putting the hottest oil in front of the condenser first with the air to oil cooler and then to the radiator, when I put the Yank in while flushing the lines. Thus I have the above numbers to post.)

Cold coolant from the cold side of the radiator does nothing to heat the trans. A brake stall will heat up the trans oil faster than the engine. High trans temps heating the coolant before the suction side of the water pump and making the trans heat go through the engine could be solved with bigger air to oil coolers. These would have to go behind the AC condenser as max useable condenser temp IMO is around 160 degrees, 300 psig, before the high side switch cuts off. Consider R134a at 380 psig is just 178 degrees. You bet 220 Degrees oil temp coming out of the trans is "normal" on a grade.

OEM aux trans & engine oil coolers are before the condenser with in/out fittings in from bottom & using stacked plate design. As the GMT400 isn't known for space up front I chose fin/plate design to replace the stacked plate design so more air flows through the cooler (s). Have yet to decide which way to go with the Cummins conversion as it relates to trans & engine oil cooling, there is some kind of heat ex-changer on side of the 12 valve I'm for trans cooling.....

Yep, there is a problem with heat load over the ac condenser my AC worked just fine after the fin/plate cooler (s) install, however I did seal all the gaps (there are plenty too) between the radiator support and the radiator which increased flow over the cooling stack.

I noticed with the CAC/IC mounted between the front chassis rails requires airflow to keep it cooled the IAT's would climb at idle or slow stop and go speeds because air was not pulled over it by the cooling fan I installed spal fans behind the CAC/IC and that solved that problem.
 
On the early Dodge OD trans like the 518 the return lube flow from the cooler goes through the case (tailshaft) into a bushing that feeds the center of the output shaft which is the lube to the thrust washers in the OD and other things.
The early OD planetaries had a high helix angle thus lots of thrust and it was easy to burn up the thrust washers
Diesels had straight cut gears- no problems Later OD's had lower helix
Chrysler, in their infinite wisdom, changed the output shaft od by about .030 so early and late do not interchange
but you can put the late planetary on the early shaft and strip the od splines real soon now- other way does not fit
I have one 92 trans with well over 250K miles with the diesel gears and no problems
When we had a warranty we would rebuild with Diesel parts (extra clutches, straight cut gears, etc) instead of getting a factory Reman. Actually the Diesel Parts were less than the light duty parts.
Trans we rebuilt- well I never saw any of them again
You can also tow in OD with the Diesel Planetaries- there is not thrust and plenty of lube for the bushings
Transgo also makes a HD Spring for the OD and it's easy to dieselize the number of clutch plates
We drilled and tapped the cooler lines to the next size bigger and reamed out the oil passages as much as possible
I may have mentioned that we went to half inch cooler lines and coolers with 1/2 in and out
makes a big difference in cooler flow and helps save the thrusts.
Charysler ATF +4 is an excellent fluid, especially solves converter shudder
You can also take the complete guts out of a later trans (47) and as long as you take everything it's an easy upgrade.
On the Torqueflyte based OD cooler flow does not go back to the valve body.
That said The Torqueflye OD can be made very strong with just a few mods as can the TH400 based Chevy trans

Transgo Shift kits, even the little ones have a mod that gives lube flow in park
Gil Younger (RIP) had a patent on it but it's now expired and most everyone has a full time lube fix for the Torqueflyte
Full time lube is also good for emergency vehicles where the key is turned and the pedal is floored as the Transgo kit has an anti drainback fix. I also specify double wrap low/reverse bands for that application
cheers
I have the 47RH with fresh rebuild and wish it was 4wd so I could use it in my Cummins conversion because it is stand alone...
 
@FellowTraveler good points on sealing the stack and different cooler design.

The AC has simply overheated this past summer with the "cooked me well done extreme number of days this year over 115, 110, 105, 100" and tripped the HPCO switch not only at idle, but, going down the road with the fan roaring. Likely due to the coolers in front of the condenser combined with less fan and absolutely a high stall Yank heat generator. Running the 19" 1998 steel fan due to a sagging engine mount and notice AC warm up at idle. Fan roaring down the road and the AC tripping the HPCO has to be related to the Yank.

Going to see if the "V" support rods between the condenser and radiator is really needed...
 
Now just get an atlas divorced xfer and your good to go. Pricey day 1, ever worry about it again- ever.
Problem with that is the driveshafts. The rear shaft in these is already on the short side, moving it back furthur would make it to short IMO. And I'm not a fan of the DODGE tranny anyways.
 
As for Coolers I just scored TWO Borg Warner Canada 9x11 plate coolers mounted in SERIES on a 1991 BIG 460 FORD VAN - fluid was new and bright red
these appear to be OEM judging from the mounting bracket and hoses but if not a first class kit-- Thank you pick a part
Big FORDS 460 and V10 also have large OIL Coolers
anyone want a pic I'll take one
 
Everything I've read, my thoughts are: deep pan and lowed filter, to avoid the fluid sloshing away from the pick-up. Biggest cooler you can get & put it before the radiator. You want the fluid warm, but not hot. I am going to have two coolers as I have the crap luck with transmissions.
 
You would need to add a scoop under the truck to put air through the pan. I've read of it being done for remote coolers, a pan is pretty low for a scoop.
Paint your deep pan matte black. Black transfers heat best.
 
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