2-3 harsh shift after rebuild in 4L30E Auto - Help!

[4thOfJuly]

I have a 4L30E in my 1994 Trooper that some time ago started showing signs of discontent. Initially it was slow to change in 3-rd then as the cold weather began it took some 3-6 seconds to engage from Park to Reverse. The problem will decrease as the temperature increased. I had no Check Transmission Light ON, no Control Module Codes and every morning I had a loud high pitch turbine noise similar to an attack aircraft under acceleration coming from under the truck.

To cut a long story short, with the help of an ATSG manual I took the 2 valve bodies out, cleaned and replaced the o-rings, seals etc. The real reason for my problem was - POOR MAINTENANCE OF TRANSMISSION FLUID! Yes, I now strongly recommend to anyone to change ATF every 20K and if possible install an extra magnetic filter inline between the radiator and the transmission. In my case the amount of gunk formed by the oil and metal particles, blocked the Pressure Regulator Solenoid in its semi-close position. Hence not enough pressure to activate the servos.

The truck is back on the road now but my problems are not over.

As soon as I started the engine I realized that the high pitch noise went away. Good!. Stall speed in all gears is now some 1900-2000rpm where before I had 2500rpm. Good!. P-R change OK, P-1 change OK! Then I drove off and had that wonderful feeling of available engine torque, Yes YEs YES! 1-2 OK, 2-3 clunk ... ups!... then OK, 3-4 OK, then brake, 4-3 OK, 3-1 (or 3-2) clunk jerk shift again....!

Basically 2-3 and 3-2 shifts are there but are not happy. All I can think is:

1) Maybe I macked-up the settings for the band apply servo! Yet I did what was asked for - Tighten the set screw to 39inlb then back-off 5 full turns then tighten the lock-nut.

2) Maybe I used a bit to much petrolatum when installing the 2 steel balls in the transmission side of the main valve body? Remember I was working from under the car so I had the transmission side facing down, so I had to use petrolatum to hold the two steel balls in place before installing the main valve body and seal!

3) Maybe I did to much of a cleaning job on the Pressure Control Solenoid? - I did remove the flow set screw from its rear to help with the cleaning then screw it back to what I thought it was its previous value. Maybe now is out of spec and puts to high a pressure in the system!

Anybody has any suggestions?

I would love to be abble to measure Line Pressure yet could not find the Test Port...!!!!. Anybody knows if it is on the L/H or the R/H of transmission and how far form the small pan edge?

Thanks in advance for your help.
Andy

PS. I thinking to wait some 2-3 weeks, then take it apart and check-it all again.