4L80E Master Rebuild Kit 1991-1995, new and ready to install. Fits the 4L80E. Ships fast from the USA.
The 1991-1995 4L80E went into Chevrolet and GMC 2500 and 3500 pickups, 2500 Suburbans and full-size vans, many of them hauling campers, plows and equipment trailers for most of their lives. When one of these early units starts slipping under throttle, takes a second to engage, or shows burnt fluid on the dipstick, this new master rebuild kit covers the soft parts for a complete overhaul. The kit pictured comes with friction and steel plate sets, a filter, a cork pan gasket, valve body and case gaskets, front and rear lip seals, and the sealing ring and O-ring sets bagged by clutch and servo circuit, which makes reassembly easier to keep organized.
Inside the case, the 4L80E holds each gear with a combination of clutch packs, a band and one-way clutches, all applied by fluid the pump pushes through sealing rings into the rotating drums. On the 1991-1995 units, cooler return oil comes back through the pump rather than the center support, the layout GM replaced in 1997. Years of heat break down the friction material and harden the rubber, and the rings wear grooves into their bores. The result is lower apply pressure at the piston and a clutch that slips. Replacing every friction, steel and seal together restores clamping force throughout the unit, while the drums, pump, bushings and carriers get inspected and reused or replaced as needed.
These model years straddle an important electrical change. ATRA documents that 1994 brought a new pressure control solenoid, new shift solenoids, a new harness and a new connector, so a 1991-93 truck and a 1994-95 truck do not share electrical parts or trouble codes. Before you commit to a rebuild, read our 4L80E shift solenoid guide, since a stuck solenoid can make a good unit start in the wrong gear or miss a shift. If the electrical side is sound and a line pressure test still shows the unit slipping, our 4L80E rebuild cost guide lays out what goes into a complete job.
This kit is listed for 1991-1995 4L80E transmissions. The clutch and seal side carries across those years, but the valve body does not: Sonnax shows the 1991 valve body uses a screw-in temperature sensor, while 1992 and later units carry it in the internal harness. If you are replacing the valve body during the rebuild, the 1991 valve body and the 1992-1996 valve body are separate parts. A 1996 unit also differs in its low and reverse servo hardware, and 1997-and-later units were redesigned for center lubrication, so this kit is not the choice for those trucks. Match the transmission ID tag, or send us your year and VIN, and browse every option on our 4L80E parts page.
Check every bushing as you tear down; worn case and drum bushings bleed off pressure and will undo a new kit quickly. A 4L80E bushing driver kit presses replacements in square without scoring the bore. Soak the frictions in ATF, lube the sealing rings, and check clearance on each pack before closing up. If the solenoids are original, the 4-piece solenoid kit is worth fitting while the pan is down, but confirm it matches your 1991-93 or 1994-95 electrical system. Pair the rebuild with a new converter, flush the cooler, and fill with Dexron VI.
| Fits | 4L80E 1991-1995 |
| Part type | Master Rebuild Kit |
| Condition | New |
| Brand | GM |
| Ships | From the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
Yes, it is listed for 1991-1995 units. The friction and seal parts carry across those years. The electrical parts and the 1991 valve body temperature sensor differ, so check those separately.
No. GM switched to center-gearbox lubrication in 1997 and redesigned several internal parts, so a 1997-up kit is the correct choice for those units.
The kit pictured includes friction and steel plate sets, a filter, a cork pan gasket, valve body and case gaskets, front and rear lip seals, and bagged sealing ring and O-ring sets for each circuit.
It is a good time to do it if they are original. A 1991-93 truck and a 1994-95 truck use different pressure control and shift solenoids, so match the part to your model year.
Fill with Dexron VI after flushing the cooler and lines. Check the level hot and in Park on level ground.
