does downshifting manually hurt the tranny?
Looking at the GM service manual for the TH350 (obviously not the stock trans for these cars, but still an auto nonetheless, and the only manual I have handy right now), it states that manual selection of 2nd or 1st gear is fine at any speed, but that 1st gear may not occur until/unless vehicle speed is below a certain point, depending on gear ratio. It is also mentioned that these lower gears can be used for engine braking.
Similar experience here. I've been using the ratchet shifter for manual operation of my TH350 car on regular occasion for many years now. It's difficult to get the detent downshifts and governor controlled WOT upshifts to be right where I want them, so for anything other than cruising I always handle the shifting manually. No issues at all. I don't do this nearly as often with the 4L60E because the automatic shift points are accurate, and the stock shifter isn't nearly as precise as a ratchet shifter (nor does the trans respond as quickly to manual shifts.)
I reused everything but the 3-4 clutch set, the band (had some minor chunks out of it), and the pump.
This is with the Trans Go HD2 kit if that makes a difference.
Manually downshifting some full manual VB's can cause issues. In a TH350 or TH400 without engine braking, if you downshift (or shift to neutral) at speed you can create an over-run condition and cause the transmission to explode.
Automatic transmissions are designed to upshift under throttle/load. They are not as strong on a downshift in many cases. It's easier to build a drag racing transmission than a street/strip transmission because the drag racing unit never has to downshift.
However, as Jake hinted, there is more to it than that. Moving the shift lever moves the "manual valve" in the trans which controls the hydraulic possibilities. For example, when you move the shifter to [D2], the manual valve closes the "D3" and "D4" hydraulic circuits and there is no way the the 3/4 clutch could then stay engaged.
The PCM in pre '08 4L60E does not read the shifter position directly, but rather via the hydraulic circuits that the manual valve activates; it uses the "pressure manifold switch" for this.
Curiously around '09 GM changed to a physical switch on the linkage, in other words, it is reading the shifter position directly.
In short, while not technically correct, you should think of the shifter position as a "preference" and not an absolute.
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I'm not worried about automatic downshifts either, as this is another thing that the transmission allows because it was in fact designed to do it. If this was a "bad" thing that produced failure in short order, then it wouldn't be part of regular operation as designed by the manufacturer.
Looking in the owner's manual under transmission operation, the only specific caution mentioned about manually downshifting is to not shift into 2nd at speeds above 65mph. If manually downshifting was overly harmful in general, it would advise against it altogether, and/or it would have been setup from the factory to prevent manual downshifting.










