So I tore apart a known working 2006 4l80e to rebuild it. When it came apart it was nice and clean with just some worn frictions in it. I did a kit on this and it went together nice. All the clearances were good, and I did lightly hone a couple of the bushings that were replaced to prevent it being too tight.

When the converter was installed and spun, it had a strange noise. It almost sounded like the ribbing of the converter was making contact with something as it would spin. There is good clearance behind the converter. I removed the converter and it seems to spin fine. I installed a stock converter and it also makes the same noise.

At this point, it must be in the pump. Does anyone have any idea of how or why the pump would make this type of noise now? I know the gears are in correctly. Any advice is appreciated.

 

Did you put it in dry?
Are you just spinning it by hand?
Is it fully seated like it should be?

 

When I build a transmission I put the finished pump (without the seal) on the converter and spin it to avoid problems like this.

 

I used assembly lube inside the pump. The converter was seated all the way. Is there any chance the stator tube could make this kind of noise? I had just the pump pulled and on the converter and it was quite. Almost seems like the weight of the converter is not being properly supported, but it has new bushings.

 

pull the input shaft out and shove it in the converter and spin. Easy to see if the noise is internal to the converter

 

my vote is its the converter. its easy for the bearings in the converter or the one-way to make noise when they are a little worn and due to the fact you cant install it without gravity being a factor on the internals. I could be wrong, but I've made it a habit of spinning the converter on the shaft prior to engaging the splines in hopes to make sure everything settles in where it should. So far so good here.

I'd try pulling the converter out and turning the internal splines by hand with a clean tool to simulate the input shaft splines, then then reinstall it in the trans to see if the noise goes away.

 

So it's been a bit since I have posted on this, but here is where I am at: (please bear with me, I just had shoulder surgery, and there are some drugs involved...LOL)
The converter is going back. When I put the shaft in it, it definitely has some issues going on. I'll update what Circle D says when they let me know. My bigger concern is this: The pump has some odd wear for lack of a better term. I honestly don't know if this was like this and I didn't notice, or if this happened after the rebuild. Best I can figure, there should be a bushing keeping this from having damage. I can not find a corresponding part that has any damage on it.

 

Do you have a picture of the torque converter? The drive tube that goes into the transmission.

 

I don't but that tube looks perfect. I was told those are a hardened part, and likely would not damage. Is there a bearing that the input shaft rides on in the converter? I am wondering if maybe it let loose, and caused a bunch of collateral damage?

 

I've never seen a pump look like that, especially one that is as you described it.
Looks like a major converter failure happened or some extreme misalignment between the engine and transmission. Or pump failure, converter failure.

Doesn't look like it came from anything you described.

 

My guess would be the pump bushing was installed crooked and walked out. You do mention resizing a few bushings. Usually thats only necessary if it's not driven in straight. And not driven in straight reduces it's press fit.

 

All of the bushings seemed to be straight. The bushings were still in where we put them, and did not show any more wear on them than when they went in. All done with a bushing driver and checked against edges for squareness. Every trans we seem to put bushings in, seem to be too tight to be able to properly check clearances in unless they get brushed with a hone. I was also told this by a rebuilder as well. They aren't ground on like crazy, just touched and greased. Circle d got the converter back today, so hopefully they will be giving me a update soon.

 

So I wanted to update this thread and put it to bed. The pump was damaged. The circle d converter was shipped back. I talked to Brian I believe at Circle D and was told when they cut the converter open, there was slag embedded in the clutch. He said it would likely go directly through the pump, trasing it.

Circle D sent me a new converter. It's all back together now and working great!

 

More than likely a spun stator tube on the pump. I discovered alot of wear on my 4l80e when I rebuilt it. The first thing I noticed from the unit I rebuilt was that the converter "walked" into the front pump cover. So much so it had grind marks on both pump cover and converter. When I pressed out the stator bushing I noticed the stator also pushed out of the pump housing. I replaced most of the hard parts in this unit as well due to high wear most likely caused by the stator tube. The 4l80e was free though, so I had that going for me.