4t65e rebuild...

UPDATE:

I decided to just take it out on the road and run it hard and see what happened. At first, it had a few problems, mis-shifting from 1-2, slow shifting from 2-3, slipping in 2nd, just a bunch of weird stuff. After running it around town and out on the highway a bit, and climbing a few hills, everything has smoothed out nicely. 1-2 shift is smooth and quick, 2-3 is the same, ditto 3-4. Downshift is quick and solid. Even 2nd has improved greatly and is slipping only a little on a very steep hill near the house, and not at all if I hit it hard. My final diagnosis is the tranny goop. I admit, I got a little silly with it here and there. So, I think it's washing out and everything is clearing up nicely. Lesson learned...a little dab'l do ya.
In the end, if I had to make the decision to rebuild it again, I would do it. The actual re-build isn't nearly as bad as getting it out of the car and putting it back in.

I know that you've said that the 2nd gear has improved a lot but I'd still be a little worried about it if it doesn't stop here soon. Once the trans gets up to temp a few time the goop should all be dissolved. I don't know what internal line pressure is inside the trans but when I tested all of my apply pistons during my rebuild I only did about 10-15 psi. I read somewhere that if you use too much pressure you can run the risk of making the seal roll a little and not to seed properly. Just a thought but to me 100psi seemed to be a little extreme.

Out of all the seals I think the ones on the input drum are by far the most difficult....so little space to work with. I agree that the actual rebuild isn't that bad just have to have attention to detail. I just did a full rebuild here about 4 months ago......and I've gotta say that the first test drive is so scary and anyone that's rebuilt a trans on their own knows what I'm talking about. Props on making your own spring compressor!

I might have spoke too soon. Just ran the car to town and it set a 0742 code. TCC stuck on...WTF???

Uh Oh!

How much glue did you use there Monty?

I didn't use any on the valves themselves. I coated them with ATF as I installed them. I'm wondering if I got a bad TC or solenoid. They are both new.

Did you inspect the TCC apply valve when you had it apart? They can get tore up with high mileage.

Also did you replace the wiring harness. Sorry if you already mentioned this...I'm too lazy to go back and read.

Yep, I inspected all of the valves. They are the dark colored hardened valves and showed no wear at all. I used the side fine pic to try to wiggle each valve in it's bore and found zero play in every valve. I didn't replace the harness, but none of the clips broke and the harness tested fine. I tested the old solenoids by using the harness and a 12v power supply to make sure the entire circuit was good. Even though all of the solenoids clicked, I replaced them all.

In any event, I think this thing is intentionally trying to p*** me off. I got up this morning, reset the code and drove the crap out of it all over the county. My intention was to note every single thing it did/under what circumstances. I took the most punishing roads I could think of (since I live in West Virginia there's plenty to choose from). I used hilly roads, curvy roads and even went out on the interstate and cranked it up to 75mph. Brought it home via the steep hill. Not a single problem. No slipping, no TCC stuck on, no mis-shifting. It ran like it was new out of the box. Parked it and checked the fluid level, perfect.

I don't know what to think now.

That's strange.

Are you going to be changing the fluid after break-in?

We ran it all day today. It sometimes mis-shifts under heavy acceleration. For instance, approaching a hill at low speed (say 1'st or 2'nd gear) and getting down on the gas to take the hill, it will wind out (while going up the hill) unless I let off the gas. As soon as I let off the gas, it will upshift and get going. Any problems only occur when under heavy acceleration or load, such as going up a steep hill. On flat ground and normal acceleration, everything is smooth as can be. No codes have been set today. I'm thinking maybe I should have replaced the TCC control valve.
As far as changing the fluid after break in, I wasn't aware there was a break in. I was planning to replace the fluid and filter on the 11th because I didn't like the idea of having that tranny goop in the fluid. I am also considering lowering the sub-frame and replacing the TCC control valve.

Just wanted to say "Thank You" for this thread, I am going to be replacing the 4th gear clutch pack on our 2000GTP shortly and I have NEVER opened up an automatic in my life. Lots of Getrag and Isuzu 5spd Transaxles but never an auto. This thread has been a great read.