So I've got about 400 miles on it thus far. My main focus has been resolving the stalling and insufficient flow ECR code. Like I think I mentioned it would only stall when coming to a stop and it wouldn't do it every time. I came to the conclusion that it was transmission related based on the fact that I could see the transmission going into limp mode just before it would stall. So when I googled 4L80e stalling I got a ton of hits that sounded exactly like my issue. The best reference I got was https://www.yellowbullet.com/forum/showthread.php?t=1472106 from a Sonnax Tech. Basically when there is insufficient flow, the TCC circuit gets starved and doesn't have enough pressure to keep the TCC disengaged. One of the culprits is reduced flow through the transmission oil cooler. The '00 transmission uses all 3/8" cooling lines whereas in '95 they're 5/16". I replaced all the cooler lines except the the all hard line because the one on the parts truck was in poor condition and they don't sell that line. My '95 line was in good condition, or so I thought, so I just used it not thinking it would make a huge difference. I decided to go ahead and fabricate a new line out of 3/8" hoping this was the cause. When I took the 5/16" line off I discovered that it had gotten pinched by the connecting rod when it came launching out of the oil pan.
I now felt for sure this must be the cause of the stumble and stalling! I spent the next hour or so copying the bends of 5/16" line into a 3/8" line. Admitedly it turned out surprisingly well for a first crack at it. Then I went to put the flares on it. The flare tool I was using did a lousy job at making the flare in spite of very careful preparation. It couldn't keep it straight and the flare ended up off center. Not wanting to have to redo the entire line I set off to find someone with the nice hydraulic flare tool to just do it for me. I ended up at a local repair shop. But now there wasn't enough room to fit his flare tool on it before the first bend. So to salvage the line he had to splice in a short piece. His bender struggled to bend the 3/8" tubing without kinking it, so what should have been a quick job turned into much more. He finally got it and ended up only charging me for materials because he wasn't happy with the quality, but it was fully functional. I was very appreciative of what he did for me.
I put the new line on and took it for a test drive.
It still stalled...
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I now felt for sure this must be the cause of the stumble and stalling! I spent the next hour or so copying the bends of 5/16" line into a 3/8" line. Admitedly it turned out surprisingly well for a first crack at it. Then I went to put the flares on it. The flare tool I was using did a lousy job at making the flare in spite of very careful preparation. It couldn't keep it straight and the flare ended up off center. Not wanting to have to redo the entire line I set off to find someone with the nice hydraulic flare tool to just do it for me. I ended up at a local repair shop. But now there wasn't enough room to fit his flare tool on it before the first bend. So to salvage the line he had to splice in a short piece. His bender struggled to bend the 3/8" tubing without kinking it, so what should have been a quick job turned into much more. He finally got it and ended up only charging me for materials because he wasn't happy with the quality, but it was fully functional. I was very appreciative of what he did for me.
You must be registered for see images attach
I put the new line on and took it for a test drive.
It still stalled...