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I rebuild the 4L60E myself with a kit from pro built transmission.
The LS Series/4L60E Rebuild Kit Pro Street Elite 1998 - Early 2006
After the rebuild the transmission did not shift right from 2-3.
The RPM flares up a little, makes the shift and then seems to brake resulting in an rpm differences in the in and output shaft for 2.5 seconds. After a few miles the transmission started leaking from the bellhousing.
The plan is to remove the transmission next week and start investigating.
Does anybody have some pointers where we should look closely?
Below a snapshot from the log and the log file itself.
You can see the flare in RPM in the top red line.
Then the bottom yellow shows the slip of 3th where you can see the 2.5 seconds of slip with a difference of 500 RPM.
It feels like loss of power but judging from the motor timing, air and fuel delivery its loss of power in the transmission.
The leak from the bell housing sounds like the pump bushing spun. As far as the shifting issue we need more info. Like what is the 3-4 clutch pack clearance set at, what are the holes in the separator drilled to, what is the travel of the 2-4 apply pin set at and what was done to the valve body? Have you ask Dana for help, he is always very helpful over the phone.
The leak from the bell housing sounds like the pump bushing spun. As far as the shifting issue we need more info. Like what is the 3-4 clutch pack clearance set at, what are the holes in the separator drilled to, what is the travel of the 2-4 apply pin set at and what was done to the valve body? Have you ask Dana for help, he is always very helpful over the phone.
Thanks for replying.
I can't remember the exact clutch clearances that were specified by Dana. I just took the biggest and smallest feeler gauge that were still in spec and concluded it was within. I grinded the pin to 0.055" clearance and after test-driving I thought this was the problem and grinded it to 0.08". I don't know exactly what all was done to the valve body Dana includes parts from different shift kits and company's.
My best guess is that there is some cross leak resulting in the binding.
Because the flare up I don't think it is the band that's not being released. But I am going to double check everything for the 3rd accumulator check valves and holes in separator plate.
The separator plate was pre drilled but I did not check all the holes, which I going to do next week just to be sure.
Being that you assembled the transmission yourself...
Dana would have left it up to you to make any final orifice sizing changes.
The 3/4 clutch clearance (and friction material), the 2/4 band clearance (and friction material), 3rd Feed orifice, 3rd Exhaust orifice, 3rd Accumulator orifice, Servo type (including set-up for 3rd accumulator spring/ springs), use of the 3-2 Control valve, and line-pressure all have to be taken into consideration when drilling the separator plate/ setting up a proper 2-3 shift and 3-2 shift.
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4L60E build problems 
