Index: T H M 4 L 8 0 - E

THM 4L80- E
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INDEX
POWERFLOW CHART AND SHIFT SOLENOID PATTERN ..................................................... 4
SHIFT SPEED CHART ....................................................................................................................... 5
LINE PRESSURE TESTS .................................................................................................................... 6
TROUBLE SHOOTING CHARTS ..................................................................................................... 7
OIL PASSAGE IDENTIFICATION .................................................................................................... 27
CHECK BALL LOCATIONS .............................................................................................................. 34
1991-92 WIRING SCHEMATIC ......................................................................................................... 35
TRANSMISSION DISASSEMBLY ..................................................................................................... 36
TRANSMISSION ASSEMBLY PROCESS ........................................................................................ 45
THRUST BEARING LOCATIONS .................................................................................................... 91
TROUBLE CODE DESCRIPTION ................................................................................................... 92
TORQUE SPECIFICATIONS ............................................................................................................ 94
UPDATED WIRE HARNESS AND CASE CONNECTOR FOR 1993 .......................................... 95
UPDATED ELECTRONICS FOR 1994 ............................................................................................. 99
UPDATED CENTER LUBE SYSTEM FOR 1997 ............................................................................ 104
UPDATED MANUAL 2ND BAND FOR 1999 ................................................................................... 113
UPDATED OVERRUN CLUTCH FOR 2001 ................................................................................... 116
AUTOMATIC TRANSMISSION SERVICE GROUP

9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156
(305) 670-4161
Copyright © ATSG 1991
2
Updated
March, 2003
INTRODUCTION
THM 4L80-E
We wish to thank General Motors Corporation for the information and illustrations that have made this booklet possible.
This booklet contains general description and the procedures necessary to repair, overhaul, or service the THM 4L80-E
electronic overdrive automatic transmission. The THM 4L80-E is a fully automatic rear wheel drive transmission. It
provides Park, Reverse, Neutral, and four forward speeds with 4th gear being overdrive.
The shift pattern is controlled electronically with two solenoids that recieve a ground signal from the Powertrain Control
Module (PCM). The PCM will vary shift points and shift feel, as it is constantly interpreting numerous electronic signals
from various operational sensors located on the vehicle. The PCM also controls the Torque Converter Clutch (TCC) apply
speed, apply feel, and the release electronically with a solenoid.
Line pressure and shift feel are also controlled electronically with a Pressure Control Solenoid (PCS) located on the valve
body. This function is also controlled by the PCM and the numerous electronic signals from the sensors.
No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form
or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.
"Portions of materials contained herein have been reprinted under

license from General Motors Corp, Service & Parts Operations."
The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.
Copyright © ATSG 1991
DALE ENGLAND JIM DIAL

FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT
WAYNE COLONNA ED KRUSE
TECHNICAL SUPERVISOR TECHNICAL CONSULTANT
PETER LUBAN GREGORY LIPNICK
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JON GLATSTEIN DAVID CHALKER
JERRY GOTT STANTON ANDERSON
GERALD CAMPBELL ROLAND ALVAREZ
9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156
(305) 670-4161
1
Technical Service Information
THM 4L80-E
CENTER GEAR BOX CHANGES
FOR 1999 MODELS
CHANGE: Beginning at the start of production for all 1999 model THM 4L80E transmissions, the planetary
pinions on both carriers were produced 10% thicker than the previous models, as shown in Figure
1. This engineering change required the addition of a .041" shim in the gear train to re-center the
sun gear in the new planetary pinions and affected several internal parts, that may create some
confusion, and thus some mis-assembly concerns.
REASON: Increased durability and reliability.
PARTS AFFECTED:
(1) PLANETARY PINION GEARS - Were increased in length by approximately .075" in both front
and rear carriers, as shown in Figure 1, for increased durability.
(2) ADDED .041" SHIM - There was a .041" shim added between the thrust bearing and the rear
internal ring gear, to re-center the sun gear in the revised planetary pinion gears, as shown in Figure
2.
(3) CENTER SUPPORT - Required a .041" recess to be machined into the center support bearing
surface, to accommodate the sun gear being re-centered in the revised planetary pinion gears, as
shown in Figure 3.
(4) SUN GEAR SHAFT - Required that .041" be removed from the bottom of the rear bushing journal,
to accommodate the re-centering of the sun gear in the revised planetary pinion gears, as shown in
Figure 4. Notice that revised sun gear shaft can be identified with a groove cut into the shaft
splines, as shown in Figure 4.
INTERCHANGEABILITY:
None of the parts listed above will interchange with any of the previous design level parts, and
none of the previous design level parts can be used in the 1999 and later units.
However, when all pieces listed above are used as a service package, they can be used to back
service "Center Lube" model 4L80-E transmissions.
The Sun Gear, Main Shaft, Rear Internal Ring Gear and all Thrust Bearings remained the
same, as shown in Figures 5, 6, and 7.
SPECIAL NOTE: Some mis-assembly examples are illustrated in Figure 8 with some
dimensional checks to prevent this from happening to you.
SERVICE INFORMATION:
Reaction (Front) Carrier Assembly (99 Design Level) ................................................ 24202051
Output (Rear) Carrier Assembly (99 Design Level) .................................................... 24202052
Washer, .041" (99 Design Level) ................................................................................. 24211821
Center Support Assembly (99 Design Level) .............................................................. 24217454
Sun Gear Shaft Assembly (99 Design Level) .............................................................. 24207264
Copyright © 2003 ATSG

104
Increased In Length
By 10% And Shim
Added To Re-Center
Sun Gear

Figure 1
105
OEM PART NO. 1991-1996 MODELS

8623921
OEM PART NO. 1997-1998 MODELS

24208848
OEM PART NO. 1999-UP MODELS

24208848
OEM PART NO.

24211821
.041" Shim
Added In 1999

Figure 2
106
1997-98 DESIGN LEVEL 1999-UP DESIGN LEVEL

CENTER SUPPORT CENTER SUPPORT
PART NO. 24217454
Flush .041" Recess
Flush .041" Recess
* *
* * * *

Figure 3
107
1ST DESIGN LEVEL 2ND DESIGN LEVEL 3RD DESIGN LEVEL

SUN GEAR SHAFT SUN GEAR SHAFT SUN GEAR SHAFT
1991-96 1997-98 1999- UP
PART NO. 24207247 PART NO. 24207264
Long
Bushing
Journal
Shortened
Bushing
Journal
Bushing
Journal
.041"
Shorter
This End
I.D.
Groove

Figure 4
108
PREVIOUS DESIGN LEVEL 1997-UP DESIGN LEVEL

SUN GEAR SUN GEAR
Deeper
Grooves
Smaller Hole Here

Figure 5

109
PREVIOUS DESIGN LEVEL 1997-UP DESIGN LEVEL

REAR RING GEAR SHAFT REAR RING GEAR SHAFT
Lube Holes No Lube Holes

In Shaft In Shaft
Lube Passage Solid Shaft

Through Shaft

Figure 6
110
PREVIOUS DESIGN LEVEL

REAR RING GEAR AND BEARING RACE
No Lube Passages
Through Splines
Round Hole In
Center Of The
Bearing Race
1997-UP DESIGN LEVEL .041" Shim Added

REAR RING GEAR AND BEARING RACE In 1999 Models
Four Lube Passages

Through Splines
Lube Passages In
Center Of The
Bearing Race
Figure 7
111
1999 SUN GEAR SHAFT 1997-98 SUN GEAR SHAFT

WITH 1997-98 CENTER SUPPORT WITH 1999 CENTER SUPPORT
AND NO .041" SHIM AND WITH .041" SHIM
Shaft Journal Shaft Journal
Approximately Approximately
Flush With Support .090" Above Support
"CORRECT ASSEMBLY"
WITH PROPER
SUN GEAR SHAFT
AND CENTER SUPPORT
Shaft Journal
Approximately
.050" Above Support

Figure 8
112
THM 4L80-E
NEW DESIGN MANUAL 2ND BAND
CHANGE: Beginning at the start of production for 1999 models, all THM 4L80-E transmissions were built
with a revised manual 2nd band that is wider than the previous design (See Figure 1).
REASON: Improved durability and reliability.
PARTS AFFECTED:
(1) MANUAL 2ND BAND - Now 1-1/4 inches wide instead of the previous 1 inch wide, and
manufactured with a revised band apply pin anchor, as illustrated in Figure 2.
(2) MANUAL 2ND BAND APPLY PIN - The band apply pin has a revised overall length, 2.730"
instead of the previous 2.530", to accommodate the revised apply pin anchor, as illustrated in
Figure 2.
INTERCHANGEABILITY:
The new design "Wide Band" will retro-fit back, but you must purchase the new design band apply
pin that is .200" longer than the previous design. Currently, it is only available in a service package
that includes the piston and the return spring, under part number 24223081, as shown in Figure 2.
"Narrow" Manual 2nd Band ........................................................................................ 24202631
"Wide" Manual 2nd Band ............................................................................................ 24210080
Apply Pin Service Package (Narrow Band) ................................................................ 24200418
Apply Pin Service Package (Wide Band) .................................................................... 24223081
Special Service Note:

If the "Wide Band" is used with the Narrow Band Apply Pin, the result will be No Engine
Braking when selector lever is moved to the Manual 2nd position, because the apply pin is not
long enough to apply the band.
If the "Narrow Band" is used with the Wide Band Apply Pin, the result will be 2nd Gear Starts
and tie-up on the 2-3 shift and tie-up in reverse, because you have mechanically applied the
band because of the length of the pin.

113
MANUAL 2ND BAND

Figure 1

114
"NARROW" MANUAL 2ND BAND "WIDE" MANUAL 2ND BAND
.995" 1.250"
End View End View
Notice The Radius Notice The Radius

On Apply Pin Anchor On Apply Pin Anchor
I.D. Groove
Overall Overall
Length = 2.530" Length = 2.730"
CONTENTS OF SERVICE PACKAGES

"Wide Band" Service Package Part Number 24223081
"Narrow Band" Service Package Part Number 24200418

Figure 2
115
THM 4L80E/4L80EHD
NEW DESIGN OVERRUN
ROLLER CLUTCH
CHANGE: Beginning in March 2001, a new design Overrun Roller Clutch was introduced into the THM
4L80E, as a running change. This engineering change affected many other related parts.
REASON: Increased durability and reliability with the new design roller clutch, by reducing the ability of the
rollers to "skew".
PARTS AFFECTED:
(1) OVERRUN ROLLER CLUTCH - Entirely new design with smaller diameter rollers and the
rollers are now trapped inside of a "Shoe" to help prevent skewing, and the springs put pressure on
the "Shoe", as shown in Figure 1.
(2) OVERRUN CLUTCH HOUSING - Requires a different ramp angle on the inner cam, to
accommodate the new design roller clutch, as shown in Figure 1. The snap ring was also moved
away from the back of the roller clutch which required a new snap ring groove that is lower in the
housing, as shown in Figure 2.
(3) OVERRUN ROLLER CLUTCH RETURN SPRING - Now requires a recess in the return spring
retainer to accomodate the relocated snap ring groove, as shown in Figure 2.
(4) RETAINER SNAP RING - New design has revised dimensions, as shown in Figure 2. The new
design snap ring is thinner and narrower.
(5) OVERDRIVE PLANETARY CARRIER - The new design has a smaller diameter roller clutch
outer race incorporated in the overdrive carrier, as shown in Figure 3.
INTERCHANGEABILITY:
None of the current design parts listed above will interchange with the previous design level parts.
They will however retro-fit back on all models, when used as a service package.
Overrun Roller Clutch Service Package (New Design) .............................................. 24222160
Turbine Shaft Assembly (2nd Design) ........................................................................ 24200128
SPECIAL NOTE:
If installing this service package into an early model, with the 1st design turbine shaft, you must
also purchase the 2nd design turbine shaft, as shown in Figure 4. The changes included shot
peening the area around the forward clutch feed hole, the feed hole diameter reduced and
drilled through the turbine shaft (See Figure 4).

116
PREVIOUS DESIGN CURRENT DESIGN

OVERRUN ROLLER CLUTCH OVERRUN ROLLER CLUTCH
Different Ramp Angle

On Inner Cam

Figure 1
117
Snap Ring Thickness = .079" Snap Ring Thickness = .060"

Snap Ring Width = .170" Snap Ring Width = .140"
No Added
Recess Recess
Added Snap
Ring Groove

Figure 2
118

OVERDRIVE CARRIER OVERDRIVE CARRIER
Approx Approx
3.215" 3.025"
Figure 3

119
"1ST" DESIGN TURBINE SHAFT
"2ND" DESIGN TURBINE SHAFT
Forward Clutch Feed

Hole Drilled Through

Figure 4
120

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THM 4L80- E

SHIFT SPEED CHART ....................................................................................................................... 5

LINE PRESSURE TESTS .................................................................................................................... 6

TROUBLE SHOOTING CHARTS ..................................................................................................... 7

OIL PASSAGE IDENTIFICATION .................................................................................................... 27

CHECK BALL LOCATIONS .............................................................................................................. 34

1991-92 WIRING SCHEMATIC ......................................................................................................... 35

TRANSMISSION DISASSEMBLY ..................................................................................................... 36

TRANSMISSION ASSEMBLY PROCESS ........................................................................................ 45

THRUST BEARING LOCATIONS .................................................................................................... 91

TROUBLE CODE DESCRIPTION ................................................................................................... 92

TORQUE SPECIFICATIONS ............................................................................................................ 94

UPDATED WIRE HARNESS AND CASE CONNECTOR FOR 1993 .......................................... 95

UPDATED ELECTRONICS FOR 1994 ............................................................................................. 99

UPDATED CENTER LUBE SYSTEM FOR 1997 ............................................................................ 104

UPDATED MANUAL 2ND BAND FOR 1999 ................................................................................... 113

UPDATED OVERRUN CLUTCH FOR 2001 ................................................................................... 116

AUTOMATIC TRANSMISSION SERVICE GROUP

"Portions of materials contained herein have been reprinted under

The information and part numbers contained in this booklet have

Copyright © ATSG 1991

DALE ENGLAND JIM DIAL

REASON: Increased durability and reliability.

Copyright © 2003 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

Copyright © 2003 ATSG

OEM PART NO. 1991-1996 MODELS

OEM PART NO. 1997-1998 MODELS

OEM PART NO. 1999-UP MODELS

OEM PART NO.

Copyright © 2003 ATSG

1997-98 DESIGN LEVEL 1999-UP DESIGN LEVEL

Flush .041" Recess

Copyright © 2003 ATSG

1ST DESIGN LEVEL 2ND DESIGN LEVEL 3RD DESIGN LEVEL

Copyright © 2003 ATSG

PREVIOUS DESIGN LEVEL 1997-UP DESIGN LEVEL

Smaller Hole Here

Copyright © 2003 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

PREVIOUS DESIGN LEVEL 1997-UP DESIGN LEVEL

Lube Holes No Lube Holes

Lube Passage Solid Shaft

Copyright © 2003 ATSG

PREVIOUS DESIGN LEVEL

1997-UP DESIGN LEVEL .041" Shim Added

Four Lube Passages

1999 SUN GEAR SHAFT 1997-98 SUN GEAR SHAFT

Copyright © 2003 ATSG

REASON: Improved durability and reliability.

Special Service Note:

Copyright © 2003 ATSG

AUTOMATIC TRANSMISSION SERVICE GROUP

MANUAL 2ND BAND

Copyright © 2001 ATSG