SunCoast 6L80E Category 4 Transmission with Billet Converter

6L80E Rebuild kit includes the following

• New Selective Pump Thrust Washer
• New Filter Assembly
• Torrington Thrust Bearing Kit
• New Bushing Kit
• New Molded Piston Kit
• All New Steel Module
• Raybestos GPZ Friction Module
• Raybestos 3-5-R Z Pak
• Raybestos 4-5-6 Z Pak
• SunCoast Overhaul Kit
• New Pan Gasket
• Sonnax Zip Kit
• Heavy Duty 4-5-6 Backing Plate Setup
• Billet 1-2-3-4 Apply Piston
• 3-5-R Apply Ring
• Billet Pump Rotor
• Triple Disc Billet Torque Converter
• Billet 4-5-6 Intermediate Shaft and Hub

The 6L Platform

The 6L80 transmission was manufactured in Ypsilanti, Michigan, at the Willow Run Transmission facility. The 6L80 was a much different transmission than its predecessor and was intended to be replaced in 2006 when it was initially released. This new unit came with a new 32-bit controller integrated into the valve body that stayed in constant communication with the ECM via GM's new high-speed can bus network.

This new design approach in the 6L80 utilizes three-way, variable-bleed solenoids to improve shift quality and consistency which are constantly monitored and corrected by utilizing GM's new adaptive shift strategies. The deep first and second gear ratios of 4.02 and 2.36 offer ample torque multiplication with a nice, tight shift recovery. The 6L80 transmission comes with a factory rating of 440 ft. lbs of torque.

The Cat 5 6L80 Rebuild

The Category 4 Suncoast 6L80 rebuild kit has everything that our Category 3 kit has with the addition of the upgraded intermediate billet shaft and hub.

The Frictions Kit

Raybestos® Powertrain GM 6L80 GPZ Clutch Pack® contains upgraded friction components manufactured with the unique blend of GPZ high energy fibers for ultimate stress and high-temperature durability. This kit also includes the 3-5 Reverse Z Pak® and 4-5-6 Z Pak® to provide solutions to common 6L80 transmission failure points. Z Paks are completely redesigned, single-sided clutch systems that outperform OE in torque and heat capacity, without coning.

Friction Material Composition

Raybestos Powertrain GPZ friction plates greatly increase transmission performance and durability. This state-of-the-art friction material far exceeds OE material to withstand high stress, high temperatures, and repeated cycling. GPZ's outstanding performance benefits are perfect for heavy-duty vehicles and high-stress driving. Testing of GPZ revolutionary friction material shows that it outperforms OE materials by as much as 20%. Plus, its performance improves as the power increases.

Recommended Use

High-stress, driving-enhanced performance applications, heavy-duty vehicles, commercial vehicles, daily-driven vehicles and as a problem solution for 3-5 Reverse and 4-5-6 clutch failure.

The Zip Kit

Sonnax Zip Kit 6L45-6L90-ZIP targets the root cause of multiple complaints by sealing the critical circuit pressure losses in the GM 6L45, 6L50, 6L80, 6L90 valve body. The kit contains uniquely designed parts to prevent the loss of pressures within the main line, clutch apply control, solenoid feed and lockup control circuits. The kit also seals multiple circuits known to suffer from end plug leakage or poor checkball sealing. No special tools are required for installing these parts.

The Zip Kit quick guide provides clear and easy instructions on one sheet to get the unit sealed up and back on the road fast. In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing information and locations at other key areas of the valve body.

• No reaming required
• Installs quickly with no special tools required
• Uniquely designed parts address root causes of valve body complaints by sealing critical pressure circuits
• Detailed technical booklet included with in-depth rebuild and inspection tips for comprehensive valve body repair

Contents

• Pressure Regulator Valve Kit
• Boost Valve Kit
• Clutch Select Valve Spring Kit
• Compensater Feed Regulator Valve Kit
• TCC Regulator Valve, Spring, Shuttle Valve and End Plug
• O-Ringed End Plug Kit
• Actuator Feed Limit Valve, Sleeve and Spring
• Center Support Seal Kit
• Vacuum Test Nut
• Checkballs (8) .250" dia.

The Backbone of the 4-5-6 Clutch

GM 6L80 and 6L90 transmissions often suffer failure of the 4-5-6 clutch assembly due to OE design shortcomings. Insufficient clutch piston-to-plate apply surface area causes clutch plate failure, especially when apply pressures exceed OE specifications. The other problem is flexing and bowing of the backing plate (coning), which is a primary source of clutch failure.

The heavy duty Sonnax 4-5-6 clutch apply piston kit 104960-01K addresses these weak areas in two ways:

1. A modified OE clutch apply piston and piston dam are used in conjunction with a specially-designed Sonnax piston apply ring.
2. A more rigid backing plate

The Sonnax apply ring increases surface area between the apply piston and OE waved clutch plate, resulting in more even distribution of apply force to clutch plates. The Sonnax backing plate minimizes the flexing/bowing when clutch is applied, drastically reducing the likelihood of clutch plate distortion.

• Use with stock clutches and OE waved plate
• Solid backing plate design outperforms OE and aftermarket plates
• Increased apply ring surface area improves clutch apply
• Reduces heat buildup

Contents

• Apply Piston
• Apply Ring
• Piston Dam
• Backing Plate

The Broken Piston

The General Motors 6L80 and 6L90 platforms commonly see cracked 1-2-3-4 apply pistons. This stress fractured piston is often due to the cantilevered stress on the cast material. This problem becomes even more prominent with customers who have had aftermarket tuning/modifications performed to increase line pressure in the transmission.

The OE part from GM has seen several revisions in attempts to correct this, but despite this, the piston still suffers from a very high failure rate.

This new Sonnax 1-2-3-4 Billet Apply Piston corrects this issue; it is manufactured from much stronger billet aluminum and utilizes a superior design. These improvements in design refinements add additional strength to prevent failure and improve performance.

This piston is a must on modified vehicles with this transmission.

Replaces OE piston #24238700 *This does not fit 06-07 units that use OE part number #24224146

The 3-5-R apply ring

Sonnax high capacity 3-5-R apply ring 104548-01 for GM 6L80 units is shorter than the OE apply ring. When the Sonnax apply ring is installed, and the OE waved plate is eliminated, this allows for one additional OE thickness friction and steel plate to be installed, increasing the 3-5-R clutch capacity by 25%. The extra clutch and steel also help dissipate heat, resulting in a significantly more durable 3-5-R clutch pack that can handle modified engines with increased power output.

• 25% more clutch capacity
• Shorter apply ring eliminates OE waved plate to allow one additional friction

The Billet Pump Rotor

The 6L80E did share one particular common bond with its predecessor: the pump rotor design. This proves to be rather unfortunate for the 6L80, because just as it shares the same design, it also shares the same failures. With increased performance comes the need for increased fluid volume and pressure. When upgrading to a 13 vane pump rotor, the additional vanes, while providing additional volume, inherently can cause a weakness due to the lack of material between the rotor blades. This will almost always cause failure in higher horsepower applications, often times causing catastrophic failure.

The Intermediate Shaft

An essential upgrade for any hard-working GM 6L80 transmission, Sonnax heavy duty 4-5-6 clutch hub and intermediate shaft (104680-36) guarantees maximum protection against shaft breakage and clutch failure in any vehicle pushing stock components to the limit.

In place of the two-piece shaft/hub, Sonnax uses a much stronger, one-piece design that eliminates the OE assembly's weak, welded connection.

The one-piece design is custom forged from ultra high-strength 300M billet steel, then heat treated and shot peened for added durability. This combination of features guards against broken 4-5-6 hubs and the risk of rear splines shearing off — chronic failures in performance cars and trucks, as well as heavy commercial vehicles.

The 4-5-6 clutch is released in 1st, 2nd, and 3rd Gears, and at high RPMs, constant oil flow is required across the spinning clutch frictions to prevent heat build-up and damaged clutches. The unique upgraded design of the Sonnax hub doubles oil flow to the clutches for significantly more protection against heat build-up and clutch failure, especially compared to other aftermarket shafts that reduce oil flow.

6L80 transmissions also have a tendency to chirp/squawk on the 3-4 shift when the 4-5-6 clutch applies. Unlike aftermarket, two-piece shafts that increase the risk of noise by eliminating the OE damper, the heavy-duty Sonnax hub/shaft can be used with the damper.

• Rugged, one-piece design eliminates the weak connection where two-piece hub/shaft assemblies fail
• High-strength, 300M steel forging is heat-treated and shot-peened for maximum durability
• Doubles oil flow to the clutch pack for greatly improved resistance to heat and longer clutch life
• Designed for use with OE dampers to minimize risk of chirp/squawk

The Torque Converter

SunCoast 6L80E torque converters come in many varieties, from heavy hauling, sled pulling, drag racing, to daily driving. SunCoast designs and manufactures their torque converters in-house. Because of this, SunCoast can supply most any request in regards to stall or torque multiplication. All SunCoast triple-disc converters are outfitted with a heavy duty forged billet steel cover and give an unbeatable lock up performance. The company's race series converter should be used in racing/pulling applications that require a higher stall RPM than a standard converter. Increased stall is usually needed in applications where a larger turbo or turbos have been installed and more RPM is required to get the turbo on boost while on the brakes (brake boosting).

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