Re: 4l80E - How much can it handle?
Don't worry about the year.
If you get a 1991 to 1996 model, do all the updates (wire harness,AFL valve fix, replace all electronics and modify the valvebody for the new Pressure Control Solenoid (PCS). Do a transgo HD2, no walk rear case bushing, wide front pump bushing and follow ALL instructions in the HD2 kit. I also do a transbrake setup now with aluminum direct drum and can also do a custom 2nd piston/clutch setup for big HP guys. These units have officially run into the 7s.
I've done billet input shafts, hubs, main shafts, I now have different gear ratio planetaries available to me as well as the transbrakes available above. 7s will require modifications but with the HP/Torque required to do 7s, I think that "buffer" zone is more than enough for 99.9% of the guys out there. Remember, this unit was designed to haul 35K pounds behind a 7K pound vehicle to begin with. Your truck doesn't come remotely CLOSE to that. Don't use the 65 pound stock TC. Use a PI,Coan,Hughes, Yank, or ProTorque. All are good quality converters but I personnally distribute PI because it can be locked up at WOT and the turbos really like the load. But you can choose your converter based on need. For example Coan will tell you that you can lock it up at WOT, but they don't recommend it. Yank is the same way. They will tell you, "yes, you can lock it up and it will hold, but will wear out after a season or two." A nice thing about the 80e is control so if you don't want to lock it up at WOT, just disable it and then it's not an issue. Just retune accordingly. I've rambled enough but to answer the question, 7s has been officially done.