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

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ballencd

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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?
 
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.
 
You can get the add on TPS kit for the controller which is a remote TPS with a cable that would connect where the the kick down cable would under the intake and run to the IP linkage. I have the same thing on my 93 for my TCI trans controller.

for the crank position sensor there are only two ways to get RPM signal to the controller. I have tried the method using the alternator but it's not reliable. swapping out the front timing cover for one off a 6.5 with the CPS sensor is the best way, but that will also require you to replace the timing chain with one for a 6.5 and the harmonic balancer of the same engine (1995 or newer engine) the other way is if your engine has a cam sensor built into the oil pump drive (where the distributor goes on a gasser engine) but those sensors are extremely hard to find if it ever goes bad.
 
All good information here.....thank you guys. I wish I had found your site before I did any ordering....bygones! I have already bought a rebuilt 6L80 so I'm invested to that point already. The shop that sold it to me (Phoenix - not liking what I am reading here on them but too late for the time being). I have a remote mount TPS but it looks clunky and seems one mounted directly to the injection pump would be easier, smarter and less prone to problems. I'll try to post pictures at the end.
I have already ordered the oil pump drive with ESS in it and I think that would be easier then anything else other then the cost. It was pushing $280 when I bought it. Time will tell.
1778098847324.jpeg
Here is the remote TPS that I have.
1778099833335.png
Here is the oil pump drive with ESS that I have ordered.
Any other pictures you need?
 
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