So the trans is back in, and truck has about 300 miles on it since the reassembly.
Shifting is good, crisp up shifts and downshifts, no flare, and all gear are present. Moderate throttle up shift occur at 2200rpm, and light throttle will get to 4th gear around 35mph.
The torque converter locks up firmly, once you are over approx 45mph on light throttle, will unlock if you let off the throttle to coast, and locks back up when you get back on the throttle (light to moderate).
If only it was that easy...
The problem I've run into is that if the torque converter is locked, then when accelerating the torque converter won't unlock until you get to about 3/4 throttle and the trans comes out of OD at approx the same time the torque converter unlocks.
Even though it shouldn't affect the lock/unlock, I checked the TV cable adjustment and worst case it's off with 1/16 of an inch of slack. I'll try fine tuning that adjustment in the morning.
Some research makes me think it might be poor electrical connection or bad throttle position sensor. I'm leaning toward the TPS since the behavior is consistent, and with enough throttle it will unlock indicating the pcm command to unlock does get to the trans.
I don't want to throw parts at it, but I'm thinking I'll take the following approach:
-adjust TV cable
- clean and dielectric grease the electrical connections to the trans
- clean grounds at the battery
- replace TPS In case it's noisy or output is flat in the middle of the travel where it's lived most of its life
Any other ideas or suggestions?
Side note: the alternator seems like it may be getting weak (I'll check connections time rule them out), and shows approx 10 volts at idle on the dash gage, but 14 once you get above idle. I don't think it's the problem, but figured I'd mention it.