Sounds like a plan.

One thing I will suggest is pressure test should happen before and after every fix, This is so you do not introduce an unknown quantity that can further confuse which I think may have happened here or a "SERIES OF UNFORTUNATE EVENTS'

 

Agreed!

 

Well like an insane person...I pulled the trans and went back through it to see if somehow I got smarter overnight. Well I didnt like the sonnax valve action for the tcc in the valve body so I took it out and fiddled with it and installed a longer spring to lock the valve at the bottom of the bore. Also the upper valve didnt want to move very freely. Not sure what is up with that. Pulled the pump apart( this is the new one I just had delivered) and the tcc apply valve would not move unless more than 60psi was applied to the orifice and then it was only partially. So I installed the sonnax valve here and it stroked fully at 45psi which I thought was much better. And While I was at it, I installed a transgo drop in pr valve and a sonnax oringed boost valve. All vacuumed out great. So back together it went. Pulled the guyts out to double check that I had installed all of the bushings and yes they were indeed in there. Installed the wider stator bushing just because new is better right? Well I didnt find any stand out deals that told me I had found the issue but I hoped that with all of the little deals it would help or change something. Well I was wrong. I even installed an extra fat oring on the input shaft to seal the converter better. Its oone out of a kit that is just small enough to fit without cutting. You can really feel it when the converter goes over it. Pressure were better than they had ever been. Line rise is instant and way up there. No change what so ever when it came to the tcc lock up. No body home at all period end of story. So tomorrow I am going to do what I should have done today and kill my truck for the sake of this mystery machine. Just updating for anyone who is following along.

 

Sorry to hear ,

 

Progress report. I took my transmission out of my truck and converted it to four-wheel-drive from 2 Wheel Dr. All the suburban transmission and torque converter back out and installed my newly converted transmission and torque converter. Test drive confirms all systems go. Nice crispy shifts with good firm lock up. Pressures are 70 at Idle 110 in reverse, max pressure is around 240 psi. Average temperature is around 180° max temperature recorded was 194. I won’t update this thread again unless I find the cause which I’m still not sure of.

 

Found it I think. So it turns out that if I use full shop pressure while testing the tcc valve orifice, the valve strokes too far into the bore. The sealing ring of the sonnax valves pops out of the bore it is supposed to seal and the top of the valve crams into the casting. Turns out all of my sonnax valves do the same thing in this 03 pump casting. Hopefully putting a spacer or check ball in the valve as a spacer will fix that deal. Thank you again Mr. Frank.

 

False alarm problem still exists.



Could the case itself somehow be to blame?

 

But you changed the case and the vb and the pump if i remember correctly along with the input drum? I would say back up and make a single thread in here with every change you have listed so far . But yes that issue with the valve is a real issue,
Of note not traveling far enough will create no lockup also just not with the pressure drop traveling to far does. So if you shimmed it to much you wont have lockup either . Only takes about a 1/16th washer. .

 

Well a 1/4 check ball might have been too much lol. And yes I did make all of those changes you just mentioned. Im going to take the pump back out again and see if I can find a 1/16 washer the right size around here. Im guessing I would find one just big enough to fit around the spring

 

Yup just big enough and thick enough to prevent that last land from dumping no more and you don't want to increase spring tension either

 

Drilled out a washer to fit over the spring. Removed the check all and now all is good to go. Woohoo!!

 

So All is fixed? working? if so like i said I think at some place in The swapping stuff you introduced a new problem with the TCC ,And again why pressure testing after each change is imperative to avoid just such a situation. But if all good finally CONGRATULATIONS have yourself a cold one lol.
On the downside you still don't know what the original issue was. its hidden someplace in the old case, vb. pump, input drum .I would mark these so that if you do use any in the future and that issue arises , YOU WILL KNOW

 

thank you and I definitely am! Yeah I need to separate them all out and go through them again one day. In the meantime try not to use them for spares lol. It works as good as my old trans just not as snappy. Of corse it wasn’t built to have snappy shifts so that makes sense. Cruised it around today with my dog and temps never climbed over 160. Nice little bump on lockup. Perfect for a daily driver I think.

 

You are always welcome, ANY TIME,

 

What size lathe do you have? 13 inch swing with gap should work.

 

unfortunately mine is a 7” mini lathe. I will be upgrading as soon as possible.

 

I have this one and its just big enough to do pumps.

Grizzly G0602 Bench Top Metal Lathe, 10 x 22-Inch