TPS question on TH400 to 6L80 transmission swap with a 6.2 diesel?

[ballencd]

I'm new to the site and have a question on my current swap. The TH400 is out and I have a fresh rebuilt 6L80 sitting on a pallet waiting to be installed. I have replaced the rear main seal which was missing about 1.25" of seal. Ready to reinstall the pan.
The vehicle a CUCV (M1010 military Ambulance) with a 6.2 diesel and DB2 injection pump. The controller to talk to the transmission is the TCM-2600, which asks for a RPM signal and a TPS. I have a oil pump drive with ESS that I am going to use for the RPM signal but am in a quandary on the TPS signal. The TCM-2600 is looking for a 0-5vdc signal idle to WOT. Is there a TPS that will bolt to the DB2 injection pump that will work? I know there is a remote TPS but it seems like there should be one for direct attachment to the DB2 since they probably needed it for the 700R4 and 4L60 transmissions but I can't find confirmation on that. Anyone have an idea?

 

[Glagulator]

Depends on which IP you have.
These are 5v. TPS’s that fit our Stanadyne IP’s.

12554488 - fits military IP’s - throttle shaft end is different.

10137417 - 93-up 6.5

14071076 - older 6.2

 

[ballencd]

It is a military truck. M1010 with the 6.2 diesel. I will pull off what is there and see if it matches that first one. Thanks for the info.
Charlie

 

[MrMarty51]

The tag on the IP may be visible.
If I cant see too good then snap a pic with the camera.
The DB2 may have been cable controlled to the TH400 or possibly vacuum.
Welcome to the forum Ballencd.

 

[Will L.]

As mentioned above- some db2 have tps and some don’t.
Idk of a tps that mounts separately to one that wasn’t designed to have it.
You might end up needing to swap to a civilian db2 to get it.

On the engine rpm- there is a couple of options. 6.5 that have the ds4 ip (injection pump) use a different crank gear in the timing chain and have a place in the timing cover for a cps (crankshaft position sensor). The cps for the ds4 uses a 3 wire, but the newer hmmwvs with turbos and the db2 ip use a two wire cps. That two wire cps will do the job.
The other way is to get a different oil pump drive. One for a 1995 civilian hummer is renamed as an ESS (engine speed sensor). That is a 2 wire rpm sensor.

The civilian pickups with 6.5 & ds4 ip also have an alternator which has internal wiring for rpm- specific sized pulley on the alternator is critical.

There are companies that make external sensors for alternators that feed to a tachometer- those might be an option.

please do show pics of what equipment you have that came with the kit for the transmission. The more info the better.

Getting a 6l80e to work behind a 6.5 is something many people thrown over $10,000 sometimes $15,000 at only to rip it out in the end.
Cover yourself 100% legally on this. The last one I remember a guy ending up dropping in a New 4l80e, eating $9,000, selling that Hummer and buying an Alpha hummer for around $100,000 instead. Lawyers involved and it never was good for anyone involved. That was less than 3 years ago and the shop, Phoenix something, never made good on it. He was working with one of the engineers for the transmission- and that guy couldn’t solve the shifting issues.

I hope you are aware of the issues you face trying to make these two fit together.


The 4L80e survives amazingly well behind a 6.5 - even one hopped up. Some people take the 4l80e and make it a 6 speed sacrificing longevity for the extra two gears for closer shifting points - the final drive and OD stay at the same points.
So it’s pretty unique circumstances that make it worth doing it behind a 6.5. When it’s behind something that goes to 8,000 rpm it makes more sense.

In a cucv- I would definitely use 4l80e, use highway differential gears, then a 3 or 4 speed atlas transfer case to get double or triple compound gearing for off road. Then in 2H you get good mpg options on the hiway.
No one has fit a twin stick transfer case into a hmmwv or hummer yet that I am aware of… believe me- I was trying to see how to make it work! Haha.