I set Intermediate Clutch to .010" clearance per friction on all 4L80E/TH400 no matter the year, 3 frictions get .030" & 4 frictions get .040" or as close as I can get.
I don't use Kolene/Nitrated steels on 4L80E's or TH400 units, It's a waste of money, Though I don't see why you can't use them. The only unit I use Kolene steels on is the 3-4 clutch in 700R4/4L60E units.
For a '95 unit.....I would use a later ('96 & up) 4L80E Intermediate Piston & Spring Steel Wave Plate, 4 .070" Borg Warner Hi Energy Frictions, 3 .076" Steels & One .100" TH400 Steel against the Wave. You may need a Chrysler A727 .106" thick Forward/Direct Snap Ring to help tighten the clearance. Good idea to upgrade the Snap Ring anyway.
You can also counter bore the early 4L80E/TH400 Intermediate Piston to accept the Late Wave....Further tightening the clearance.
The .070" Hi Energy Frictions are FAR more durable than the .080" Cellulose Frictions, If you insist on .080" Frictions.....Run Raybestos GPZ Hi Energy Frictions.
Early 4L80E's use a really small Intermediate Feed Orifice because the lack of a Wave Plate, Using a Late Wave.....Drill to .093" for stock stall applications.
In the 1200 rwhp capable 4L80E 2005 based core that you helped me build I'm running the following:
-36 sprag aluminum direct drum with no front band so no engine braking in 2nd. I have a case saver where the band was.
-The drum uses ford c6 style intermediate frictions that fit around the race but comes with 5 frictions and 5 steels that are only 0.063" thick. Not good for heat, and as we know, 5 int frictions is overkill. I went instead with 4 smooth raybestos c6 frictions and standard 4l80e steels that are thicker.
I used an TH400 thick 0.060 wave plate and an intermediate piston from a 91-96 4L80E as a late 97+ piston cannot work with the .060" wave due to height differences. My intermediate clearance is set at 0.035" dry. I run a Coan billet intermediate pressure plate and a 727 snap ring (A22878C) that is 0.106" thick.
-wave plate 1x .066" 34125
-intermediate steel 1x .100" 34124 (enlarged ID by .080 so that it fits around the race of the 36 drum)
-intermediate steel 3x .076" 34124E (enlarged ID by .080 so that it fits around the race of the 36 drum)
-4x .078 smooth frictions 36106S1
-COAN 0.28" plate 102818
I'm running a jakes D3 transbrake, and the shift orifices in the plate are not drilled any larger than they already were as supplied. 3rd comes pre drilled to 0.118" and 2nd @ 0.140", a stock plate is .059" for 2nd and 3rd.
I used the stronger TH400 intermediate spring retainer, and 12 TH400 springs in the intermediate piston.
I run a 3600 stall and the car shifts smooth, without jaw shattering shifts.
We'll see how the intermediate stack holds up over time!