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Im building a 4l60e and having a problem with endplay on the front half of the trans. Back end has good endplay (.016 ish) The front end is from another trans, I put the new thrust washer in the input housing that rides on the sun gear in the front planetary,put the thickest selective washer I had (.125) under the torrington on the top of the input housing (around the input shaft) and then assembled the pump into the casing. I some how have about a 1/4" of end play. I thought wow, well Ill try another input housing and pump i had left over from other builds, still the same problem. I've verified correct install of the bearings, but still have alot of end play. What are you thoughts, where should I be looking. I compared the sun gear to others I had laying around and the height appears correct. I've had the front end in and out of the trans probably 15 times double checking everything. I've built quite a few 60e's but I am out of ideas.
Did you change the sun shell to(or from ) one of the aftermarket type . The rear sprag race on some aftermarket type shells is ground/cut down to make clearance for the bearing that they add . You say that your back half clearance is ok . What are you refering to , there isn't really a good way to check that clearance unless you are thinking it is ok because your output shaft snap ring goes in ok . I would make sure you tear it down all the way to the rear bearing and see if you have a bearing missing .
Most factory parts are made with a very close tolerance and will usually interchang with very little effect on endplay!!
wow lol .250 clearnce that is about the thickness of a bearing does your unit have a bearing on the back of the front planet to the shell instead of a washer you may have left that out or maybe you used a different planet ring that is made for the bearing make sure for some weird reason the bearing in the planet carrier is not missing and you have a bearing under the planet carrier between the ring and the carrier
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Hey man did you figure this issue out? I'm having the exact same issue and can't find anything that could be missing. I don't feel comfortable shimming something that much and possibly throwing something off.