4L80E Master Rebuild Kit 1996, new and ready to install. Fits the 4L80E. Ships fast from the USA.
A 1996 Chevrolet or GMC 2500 or 3500 pickup, a 2500 Suburban, or a full-size Chevy or GMC van with the 4L80E has usually covered a lot of miles by now, and plenty of them were towing miles. If yours slips under load, engages late on a cold morning, or the fluid has gone dark and burnt, this new master rebuild kit is listed specifically for the 1996 unit. The brand on the listing is Borg Warner, with a 1-year warranty. One order supplies the frictions, steels, seals and gaskets to overhaul the transmission completely instead of fixing one leak or one clutch at a time.
A master kit renews every clutch pack and seal so the rebuilt unit applies each clutch with full clamping force and holds line pressure. What makes the 1996 build different is where it sits on the timeline. It is the last year of the original layout, where cooler return oil comes back through the pump; Transmission Digest documents that GM moved the cooler return to the center support in 1997 and redesigned many internal hard parts around that change. It also carries the 1994 electrical update, and ATRA's Technical Bulletin 266 lists what changed that year: a new black Holley pressure control solenoid in place of the silver Bosch part, third-design A and B shift solenoids, a new harness and connector, and new trouble codes. And on the low/reverse servo, Sonnax lists its servo spacer kit as fitting 1996-and-later units, so a 1996 is the first year with the spacer style rather than the earlier adjustable pin.
Rule out the electrical side before buying a full kit. A 1996 uses the 1994-and-later solenoids, and a stuck or open shift solenoid can mimic a slipping clutch; our 4L80E shift solenoid symptoms guide explains how to tell them apart. Then run a line pressure test. If the pressure is in spec but the unit still slips, or the pan shows burnt friction debris, the clutch packs are worn and the overhaul is the right call. Our 4L80E rebuild cost guide covers what else commonly gets replaced so you can plan the whole job.
This kit is listed for the 1996 4L80E. Because 1996 sits right before the 1997 center-lube change, confirm your unit is a 1996-style pump-lube transmission by reading the ID tag on the case, especially if the truck was built late in the model year or the transmission has been swapped. Do not mix 1997-and-later center-lube hard parts into a 1996: Transmission Digest warns that sun gear shafts, center supports and carriers changed with the redesign. If you have a 1997 or later unit, use the 1997-2011 master rebuild kit instead. Every 4L80E option we stock is on the 4L80E parts page, and you can send us the year and VIN for a fitment check.
Tear the unit down fully and inspect the pump, drums, bushings, sprags and carriers, because the kit covers soft parts only. On a high-mileage 1996 check the drum seal surfaces and splines closely; a scored drum will eat new seals, and the 4L80E clutch drum for 1991-2000 fits this era. Check the low/reverse servo assembly for the spacer-style setup and inspect the servo piston for cracks. Soak the frictions in ATF, lube every seal before assembly, measure end play, and set each clutch pack clearance to spec. If the valve body has worn bores or the shifts were already soft, a 1993-1996 4L80E valve body matches this year. When replacing the pressure control solenoid, use the black 1994-and-later style; ATRA warns the earlier Bosch part must not replace it or high line pressure will result. Fill with Dexron VI.
| Fits | 4L80E 1996 |
| Part type | Master Rebuild Kit |
| Condition | New |
| Brand | Borg Warner |
| Ships | From the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
Do not assume so. 1996 is the last year before GM moved the cooler return to the center support in 1997, and several internal parts changed with that redesign. Use the kit listed for 1996, and read the ID tag on the case to confirm your unit.
The black Holley-style solenoid introduced for 1994. ATRA notes the earlier silver Bosch solenoid must not be used to replace it, because the oil channeling changed and high line pressure will result.
Anything that fails inspection: worn bushings, a scored clutch drum, damaged sprags, or a worn valve body. Many rebuilders also replace the pressure control and shift solenoids while the unit is apart.
The listing shows Borg Warner as the brand with a 1-year warranty. The kit is new.
Dexron VI ATF. Soak the new frictions in ATF before assembly, and check the level hot after the first drive.
