I had a member PM me with a question; "I'm just interested in what you learned the hard way? I appreciate your input." I decided to share the reply here, maybe others would benefit from my experience.

I'll try to briefly summarize what happened.
It started with a good plan, upgrade a 1987 K3500 7.4 liter / TH400 to a rebuilt 4L80E using 16168625 PCM.
Step 1, upgrade to the 16168625, this went flawlessly!
Step 2, install the 4L80E, this step was full of headaches because the 4L80E would not shift on the first test drive.
Step 3, Troubleshooting - nothing wrong.
Step 4, More troubleshooting - still nothing wrong.
Step 5, Replace valve body - still nothing wrong.

Step 6, Try to find a 16168625 4L80E .bin file - nothing, nothing and still nothing. There is not a factory 16168625 4L80E .bin file ... PEROID!!!
Step 7, Try a 16197427 with the same Memcal, Moates.net adapter board and the same $31 .bin that was in the 16168625.
Step 8, HAPPY DANCE!!! The transmission shifts!!!

dave w