@clinebarger I got one for ya. Well this one is a first, at least for me. Didn't have this issue in previous builds.
2004 late 4L80E case
Sonnax no walk bushing inverted, confirmed roller bearing makes contact with output shaft and that the bushing is not impacting rear end play in any way. Bushing is black side facing the case.
The rear endplay is 0.005"
So stacking it up to the center support and leaving the low roller clutch and reverse band out, with the bellhousing facing the sky, the output shaft rotates both directions. As soon as you tighten the center support bolt to 29 ft /lb (or even 15 ft / lbs) and change nothing else, it becomes very difficult to turn the output clockwise and it gets to a point where the binding is really bad. You have to rotate it counter clock wise 1/4 a turn just to get it to start moving clockwise again. It will rotate with one hand for about a turn and a half, and then bind really bad. This is with beveled snap ring out. Tightening the bolt is essentially centering the center support, so it's an assembly issue or a part issue. If you add a direct drum to the mix, (just the drum itself, no frictions anywhere in the case) it becomes almost impossible to rotate clockwise. Counter clockwise is fine. Rotating it by grabbing the direct drum from the top is fine, rotates in both directions. So back to just the stack up to the cs:
- Sun gear is in correct orientation
- Everything is lubed
- All washers and bushings and bearings in the stack are accounted for an in correct orientation, triple checked
- Bushings in the output, center support, and front planet appear to be straight and at correct depth. About to replace them just to see if it makes a difference.
- Reverse band removed for this testing
- Low roller clutch removed for this testing
- All the parts are the correct year and what originally came in the case
- None of the rear servo or accumulator parts are installed
- Not seeing any wear on the hard parts that would cause this issue
Of course if you remove the sun gear tube, everything rotates easily in both directions. This leads me to believe that perhaps the sun gear tube is warped, or the billet main shaft is warped, or something is up with this case or another hard part causing it to not be on center. The main shaft is new. When I put a calibrated straight edge against the sun tube and main shaft neither appear to be warped. Durabond fluted bushings in the tube were finish in place, as they didn't go on the main shaft easily so they had to be honed. Bushings were pressed in and should be straight. They look straight.
Plan is to get a new sun gear tube on Monday, press in the new bushings and hone if necessary and see if the problem persists. If so, then I'm going to get the main shaft checked to see if it's bent. What am I overlooking here?
2004 late 4L80E case
Sonnax no walk bushing inverted, confirmed roller bearing makes contact with output shaft and that the bushing is not impacting rear end play in any way. Bushing is black side facing the case.
The rear endplay is 0.005"
So stacking it up to the center support and leaving the low roller clutch and reverse band out, with the bellhousing facing the sky, the output shaft rotates both directions. As soon as you tighten the center support bolt to 29 ft /lb (or even 15 ft / lbs) and change nothing else, it becomes very difficult to turn the output clockwise and it gets to a point where the binding is really bad. You have to rotate it counter clock wise 1/4 a turn just to get it to start moving clockwise again. It will rotate with one hand for about a turn and a half, and then bind really bad. This is with beveled snap ring out. Tightening the bolt is essentially centering the center support, so it's an assembly issue or a part issue. If you add a direct drum to the mix, (just the drum itself, no frictions anywhere in the case) it becomes almost impossible to rotate clockwise. Counter clockwise is fine. Rotating it by grabbing the direct drum from the top is fine, rotates in both directions. So back to just the stack up to the cs:
- Sun gear is in correct orientation
- Everything is lubed
- All washers and bushings and bearings in the stack are accounted for an in correct orientation, triple checked
- Bushings in the output, center support, and front planet appear to be straight and at correct depth. About to replace them just to see if it makes a difference.
- Reverse band removed for this testing
- Low roller clutch removed for this testing
- All the parts are the correct year and what originally came in the case
- None of the rear servo or accumulator parts are installed
- Not seeing any wear on the hard parts that would cause this issue
Of course if you remove the sun gear tube, everything rotates easily in both directions. This leads me to believe that perhaps the sun gear tube is warped, or the billet main shaft is warped, or something is up with this case or another hard part causing it to not be on center. The main shaft is new. When I put a calibrated straight edge against the sun tube and main shaft neither appear to be warped. Durabond fluted bushings in the tube were finish in place, as they didn't go on the main shaft easily so they had to be honed. Bushings were pressed in and should be straight. They look straight.
Plan is to get a new sun gear tube on Monday, press in the new bushings and hone if necessary and see if the problem persists. If so, then I'm going to get the main shaft checked to see if it's bent. What am I overlooking here?
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