Please help transmission rebuild problem

[phix-]

Hi all, I recently had a member show me this site and I have been searching for about the last 48hrs straight for some idication that someone else has had a similar issue. My truck is a:

96 OHV rebuilt
4r55e rebuilt with new custom stall converter
Rayesbestos soft parts (clutches, bands, etc.)
Central Valve bodies rebuilt valve body
B&M 11x8 cooler
Mobil 1 synthetic ATF

When being rebuilt the transmission was questioned as maybe a band was out sack but other than that the trans was ok and probably had about 150k on it. After the rebuild, I started getting a p0741 code. The shop dropped the trans again and saw that the outter seal on the stater pump shaft was pinched and causing the code. During this drop we also warrantied the valve body to ensure maybe something funky was with the solenoid.

I get the truck back and everything is great for the drive home and most of the next day. Take the truck to work and it starts doing the following.

When accelerating passed 40, 45-50mph is reached the truck will either over-rev will going to gear 4 and shift a tad hard. Then from what I am told I feel an additional shift point which is the torque converter. Now this can happen up 2 times finally catching and moving forward and beginning to boogie down the road. Now in other cases where I throttle into 3rpm it will endo and stall (sometimes light, sometimes the truck feels like it dies completly for second) If I turn OD off it locks hard into 3rd, turn OD back on rpm drops as it should. Trans shop says it's the converter, converter shop says trans shop.

That's about it, any and all help is greatly appreciated. I am due to drop the truck off today and have the converter taken out and cut open.

 

[phix-]

Also I have a question about what happens during deceleration to braking to accelerating?
Example:
40 > 45 (3rd gear to 4th) > lock up
So if I brake tc unlocks, locks backup when I apply throttle?
What is involved that could cause a stall?
I read that the TPS can cause this, but would there be any other symptoms?

 

[wood1]

http://www.explorerforum.com/forums/showthread.php?t=310331

Why the custom converter?

EDIT Bad link, sorry... that was the ATSG manual

 

[phix-]

I was in the process of moving toward a cam and has a m90, so my tuner recommended a 2100 stall.

 

[phix-]

Alright so I started reading the PDF and it mentions the powersteering pump and a/c compressor. I replaced my power steering pump and it still makes noise (heavier the more I turn the steering wheel). Though it works as it should, it needs a fluid flush. Though it does make noise and that worries me.

 

[phix-]

Ok, seems the TSS and VSS symptoms (despite no codes) are what sum up what I feel or can understand while driving. Also, after the trans was dropped some brass shavings were found on top of valve body and also in the pan which was noted as clean.

 

[wood1]

Ok, seems the TSS and VSS symptoms (despite no codes) are what sum up what I feel or can understand while driving. Also, after the trans was dropped some brass shavings were found on top of valve body and also in the pan which was noted as clean.

I think that the only thing in that transmission that is made from brass would be found on page 8 of the manual and is not normal wear, especially on a new transmission. Just saying... know what I'm saying?

 

[drdoom]

I think that the only thing in that transmission that is made from brass would be found on page 8 of the manual and is not normal wear, especially on a new transmission. Just saying... know what I'm saying?

You think maybe it is a thrust washer?

 

[syn-]

I have been there and still have yet to find the issue.

 

[wood1]

Seems like a logical conclusion but I've never seen the insides of the 4R55. What else is made from brass?

 

[phix-]

Here is the thing, let's say I take the converter to the manufacture and they cut it open. If there are no issues I would believ they did something wrong in the rebuild. I asked if they replaced servos and he said they do. It's strange that I can keep my foot on the pedal and the see/feel the torque converter unlock. Then lock, though if I push the brake pedal and let it coast down then throttle back into there is a drop in rpm and lock. Though the stall then over-rev, harsh shift, and then lock. Seems like it's a control issue, the motor feeling like it dies is concerning. Trans shop also said that my torque converter has brass in it?

 

[wood1]

If that's the case then your converter could be the problem. Locking, unlocking, falling on it's face... especially where the VB has been replaced. It will be interesting to see what the inside of that converter is like.

syn-, you the builder or what? I don't catch your meaning.

 

[Alsmarineparts]

Take your time

OK IM GOING TO GIVE EVERYONE A LAUGH AT MY EXPENCE AS YOU CAN SEE FROM MY POSTS I WAS HAVING TRANNY TROUBLE, WELL AFTER A FLUID CHANGE SHIFT KIT AND VALVE BODY. . I GOT A CODE THAT THE SOLENOIDS WERE BAD A B C AND D , GOT A NEW SET AND WIRE HARNESS TOOK TRANNY APART 2CD TIME PUT THEM IN FINISHED AND TESTED. ARRRGGGHHH NO FIRST GEAR STUCK IN THIRD. GOT SAME CODES. TOOK TRANNY APART 3RD TIME CHANGED A B C D AGAIN AND WIRE HARNESS AND ADJUSTED BANDS CHANGED ALL SENSORS. TESTED AND WAS THE SAME. STILL CODES ALL SOLENOIDS MALFUNCTIONING. AT THIS POINT I HAD ENOUGH. I PUT IT ON CRAIGS LIST AND EBAY WENT OUT TO WASH IT AND MAKE SURE EVERYTHING WAS TIGHT WHILE I WAS UNDER THERE I SAW THE STUPIDEST MISTAKE I HAVE EVER MADE I FORGET TO PLUG IN THE SOLENOID PLUG ON THE SIDE OF TRANNY. I PLUGED IT IN AND IT DRIVES LIKE NEW.
JUST GOES TO SHOW DONT FORGET THE LITTLE THINGS!!!

3 sets solenoids $400 3 gaskets $28 pulling plug out of my ass and putting it in the tranny priceless

 

[phix-]

Alright, so where is this plug? My guess left side?

 

[Alsmarineparts]

plug

yep thats it

 

[phix-]

Out of curiosity I noticed today that the inner diameter of my airfilter holder does not match the 90mm maf. I measured the hole and seems it's the stock diameter.

So, airfilter>adapter plate>MAF>intake.
50'ish>90mm>intake

Could that cause a harsh engagement when throttle is re-applied? Figuring the PCM believes it based on airflow that it can go into 4th, but after it tries it realize the vehicle is not moving as fast as th air meter reports.

 

[wood1]

Did you have the converter cut open yet?

 

[phix-]

No, I am actually I on my way to have the adapter plated widend so I can see if that is the issue. Though, does it sound like that could cause it?

 

[phix-]

Alright, so Wood1 your the man for pointing me into the ATSG. For anyone reading this who uses a lighting maf for their setup make sure your adapter plate matches! I used one off of my k&n fipk and despite me getting it to mate with re-drilled holes I did not adjust the internal diameter causing the velocity of air reading to be off and possibly even cooling the wire down causing the PCM to engage 4th too early. It may have also tried to engage 3rd an 4th. Though not sure.

To anyone curious on how I figured this out. I took a square mesh metal screen, 4 zipties, and removal of filter+adapter. Drove with just the MAF and the mesh covered over the hole to protect the sensors. Cleared up instantly! No more stalling or endoing!

 

[wood1]

Really?! That's great that you figured it out. How about some pics of your supercharger set-up?

Still wondering about the brass filings thou. Hope it wasn't anything that is going to cause you issues later on.