For the part numbers, I went to:
https://www.transpartsonline.com/TRANS_PARTS_FILE/tpcat.php?TransPartsOnline=400&TransPartsType=400
and in the search bar I entered 965, which comes back showing:
PISTON, FORWARD / DIRECT CLUTCH (Aluminum / No check ball) 64-UP does not use dished type cushion plate #127 uses waved type plate
Item #U34964
PISTON, DIRECT CLUTCH (Aluminum / WITH check ball) 64-UP does not use dished type cushion plate #127 uses waved type plate
Item #U34965
I'm buying Jakes Billet Aluminum Direct drum for use with a 36 sprag. I will check with him to see if it has a bleed checkball, and will then purchase the correct aluminum piston, either one with or without the checkball. Do you already have machined aluminum pistons for sale on hand? I saw a video about machining off 600 off the piston to get the tolerances correct, but I'm not sure if the depth of the Billet drum will be the same as the depth of a 4L80E drum or not. Will need to check with Jake.
So assuming all the clearances are proper, I'm looking at:
TH400 direct clutch piston machined for proper clearance
TH400 direct clutch spring retainer U34984 and 16 springs (TH400)
Cushion plate, waved 6 lugs 34127EA taken from a late model 4L80E (use existing one from 05 core)
6x direct steels .090 #34126A
6x direct clutches .080 B34106E
4L80E late model pressure plate D34146B (use existing one from 05 core)
TH400 snap ring U34877 (not the 4L80E snap ring)
Intermediate setup:
4L80E intermediate clutch piston, (1.00" TALL, USED with integrated waved steel) part U34962C (use existing one from 05 core if available)
TH400 intermediate clutch spring retainer U34982A, using twelve TH400 4L80E springs U34972 (do not use cupped outer edge retainer U34982)
4L80E snap ring U34872 taken from a late model 4L80E (use existing one from 05 core)
4x intermediate clutches, 0.070" A34104EA
1x "waved" steel plate. Black with little tangs along the inside diameter. D34125A
4x intermediate steels, late model 4L80E style .076" thick #34124E
4L80E pressure plate (use existing one from 05 core)
Snap Ring, Holds Intermediate Pressure Plate In, stronger snap ring part A22878C
I plan to purchase:
-Borg High energy Friction plate kit 34035KIT or 34119EA
-Steel plate kit Raybestos (34139EA) 000592
and then add the additional .080 direct friction and .090 direct steel
I found that it's cheaper than getting the waves and frictions together, at lease at my part sources.
Does D34125A intermediate wave plate already come in a 4L80E 05 core? If so I can remove that off the purchase list.
Also I read that it's a good idea to used a waved steel cushion plate from a TH400. 12 lug .060 part 34127. Do you advise this?
Disregard the 0.077 steels in the last row of the image below, but basically I think we are looking at:
Mine does not have the Pressure Relief Valve mod done.
Plug the reverse feed in center support. Keeps 3rd/Reverse oil from leaking between the Support & Case - NO
Remove/omit the second from the top Sealing Ring on the Center Support - YES
The D3 Valve body should already have and oversized AFL valve
Stock TCC Reg valve is OK
The D3 valve body will come with a pressure regulator spring
I plan to just follow the D3 instructions, with the drill mods you OK above.
Are Bosch TI2132 Titanium-Coated Drill Bits good enough to get the job done?
Should I replace any of the internals inside the pump like the springs or valves with stock equivalents, or at least take it apart to clean it?
How critical is it to note the bushing locations that I'm about to replace? I don't need to use a depth mic or anything on them do I?
I see here that you explain how to measure tolerances and endplay in this link below, but do you know of a good video that shows it being performed? I have a Fine Adjustment & SAE Dial Test Indicator & 22 Piece Anvile Point Set with magnetic base, a set of angled feeler gauges and a set of straight feeler gauges.
https://bobistheoilguy.com/forums/threads/4l80e.271222/page-2
I have the tolerances you listed noted below:
Total Rear Unit.....003"-.008" (Rollerized)
Reaction Carrier to Center Support......008"-.015"
Direct Drum to Forward Hub......003"-.008" (Rollerized)
Front unit.....005-.008" more/greater than the Rear Unit
If that ASTG manual would ever arrive, I would probably have the answers to many of these questions lol....