48re problems after rebuild

[Smoke Eater]

I just finished a rebuild on my 04 3500's 48re. It ate a thrust bearing in the overdrive unit and burned up the direct clutch pack. I cleaned everything up and flushed out the valve body, tc, and trans cooler. Did a complete rebuild, bearings, seals, bushings, frictions and steels. Made sure everything was within proper tolerances. This isn't my first rebuild. I do have a Goerend valve body, sonnax billet servos, upgraded apply lever and strut and a billet tc.
The problem is it starts out in 3rd, and won't go into overdrive. I can manually downshift into 2nd, but not 1st. It also won't go into manual 1st. Pretty sure I'm going to find a problem in the overdrive unit, but I'd appreciate any other ideas. I did upgrade the overdrive piston support to a heavy duty model that has an o-ring just behind where the snap ring goes that holds it in place. I'm wondering if that o-ring failed, I had to replace the original o-ring and was unable to find a viton o-ring in that exact size.
I'll be pulling it back out tomorrow and tearing it down again. I'll post my findings tomorrow afternoon.

 

[Timd32]

Have you checked for any codes, that 3rd gear start sounds like the TCR has removed power to pin 1 of the Trans.

Do you have the ATSG book it has some info on page 18, and then codes listed on Page 25.

Could swap the relay with a spare possibly.

Odd how Manual 1st does not work, is that rooster comb deal that works with your Manual valve not back in properly. Goerend has a video on that on youtube.

I know I've read the trans temp sensor will put it into that 3rd start only, but the Manual 1, 2 , 3 is separate from the electronics. That part should work.

Good luck with your fix.

 

[Smoke Eater]

I was thinking the same thing. Just finished pulling the codes, there's plenty of them. P0973, P0868, P2769, and P0713.
I'm going to read a little more, but it's looking like it's time to swap out the overdrive & lockup solenoid, governor pressure sensor, and governor pressure solenoid.
I did clear the codes, I'll start it back up in a bit and see what happens.
The whole thing with not having manual first is what's throwing me off. Hopefully it's nothing major.

Thanks for your help.

 

[Ozymandias]

Some dirt inside the valve body.
Did you take it apart for cleaning it?

 

[Smoke Eater]

No, but I should have. I just used the parts washer, agitated and flushed it out several times.
The original symptom was loss of reverse and burned fluid, all of the shifting was fine. After taking the overdrive unit off, the problem and cause were obvious. I ended up taking a shortcut that I shouldn't have.

I cleared the codes and took it out, it starts in 2nd and shifts to 3rd. No first in manual or drive, tow/haul makes no difference, no overdrive either.

I'm going to check the wiring harness and the 8 pin plug next. If I find nothing, I'll drop the pan and take the valve body out to give it a thorough cleaning.

 

[Smoke Eater]

Sometimes it's the simple fix. I checked the 8 pin plug for power and had none. The female end of the plug had been replaced years ago. Took all the tape off of it and found the power wire disconnected and several loose. Fixed them all, and no more problems.
Thanks to all for your help.