Re: 4l80e rebuild and syty transfercase questions
Sticking with the SYTY transfercase means that a adapterplate is a must. JSM, CK Performance or Raceprovenmotors got'em or can make them for you.
There are diffrent ways for matching up the out- and input shafts between transmission and transfercase.
1. Replace the 4x4 stock output shaft in the transmission with a billet outputshaft made by CK Performance. I have seen pictures of "cut" TH400 outputshaft that works. (its in a thread on syty.net)
By cutting it alot of heat will weaken the shaft...and you are planning making big HP. Waterjet cutting?
2. Stick with the stock 4x4 4L80E outputshaft and change the transfercase inputshaft that fits the 4L80E outputshaft. Maybe Mike Lee at Raceprovenmotors have the transferscase shafts ready to be made by order.