I knew going in that the 4L60E's strength is marginal in this application and mine is probably original with 110k, so there was a chance that I might push it over the edge. That was okay though, because I had a backup plan.
After thoroughly test driving it with the new tune, starting out easy and getting more and more aggressive, it became apparent that the trans wasn't going to be quite happy with this. In most situations it was just fine, but primarily during the 4-2 downshift, the rpm was flaring up a bit past the point it should stop rising, then settling back down into the new gear. I immediately logged this and some extra things and sent it to Justin. He told me that the engagement of the 2-4 band was definitely struggling as well as on the 1-2 upshift, and that he would increase the torque management on those shifts, but that was just a stop-gap measure for probable transmission wear (if the fluid level was good, which it was). That made sense to me, and was enough to kick the backup plan into action... right after putting the stock TCU tune back in it and driving it easy in the meantime.
One of my goals with this project is to have little to no downtime, because I've had problems with that in past projects and it's too depressing to have my hard work sitting pointlessly in the garage or driveway for long periods of time. I'm done with that. Mods and repairs need to happen one at a time and in a timely manner, and if I can fix something before it breaks, then more better!
So, knowing from the beginning that the stock trans might be on borrowed time, I set to researching early-on the best route to take considering my goals and resources. A 4L80 is out of the question because of their gear ratios and innefficiency as well as swap difficulties (for me). I really want a fully-functioning 6L80 in there, but I read and researched the hell out of that and deemed it to not be a feasible swap for me. I then looked into built 4L60E's for the first time in 15 years or so, and much to my suprise, a LOT has been accomplished with them in the last 8-10 years. Built with the right parts by the right people, they can now reliably handle a good amount of power and abuse. I still find the same stories as always about local joe-shmoe trans shops swearing their 4L60 builds can handle a million horsepower then blowing up almost immediately under near stock power levels, and I'm not going to play that game either, so I looked into the highest rated 4L60 builders in the country, then the highest rated of those. What I found was that RPM Transmissions seems to sit in the #1 spot, and they have had many very fast customer cars (and some off road rigs too) prove it time and time again. Also, while a drag car isn't a direct comparison for my use case, it still says a lot when their 4000lb full-slick 2010 Camaro hits hard repeatedly running high 8's with a 4L60E. RPM Transmissions does build the most expen$ive 4L60E's I could find, but it seems to be a case of getting what you pay for here.
So I emailed them and asked what build they would recommend for my use case, which involves everything I've told and shown you in this thread and then some... behind not just the 5.3, but behind an L9H 6.2 truck engine (400hp/420tq) because that might happen someday. :shifty: they said their Level VI build is up to all that, which is what I had guessed based on my research (either a Level V or VI anyway). So after a few more Q&A's, I ordered one for Wanavee last week, and it is currently being built. :thumbs:
Here is what goes into that (from their website):
*Media blast transmission case
*RPM Level V 3-4 clutch pack
*RPM reinforced sunshell with collar and bearing
*Heavy Duty double caged 29 element sprag
*4L65E low roller clutch
*Billet 4th gear servo
*Transgo HD-2 shift kit
*Corvette Servo
*Wide 2-4 band
*Updated aluminum accumulator piston
*Bushing kit
*New shift solenoids
*New GM valve body spacer plate
*Seal & gasket kit
*GM Filter
*RPM Spec clutch and band clearances
*RPM sleeved input drum
*Billet over-run piston
*GM 5 pinion planetary gearsets - front and rear
*NEW Extra WIDE Heavy Duty double caged 29 element sprag
*300m Billet output shaft
*4L65/70E low roller clutch
*Each transmission is dyno-tested before shipping
http://www.rpmtransmissions.com/page28.html
Soon Wanavee will be back at World Tour Off Road getting its strong new piece of hardware... and some other stuff too. :shifty: