The Failure Dynamic has a few vectors:
(1) Failure to Install the Torque Converter with the CORRECT SPACING in between the TC Mount Pads and the Contact (3) pads of the Flex-Plate such that the Outer Orbit of the Flex-Plate is NOT bent or warped out of traveling in a "Perfect Circle" and in a Straight Line. Measure for these proper separations and install Hardened Washers in between that balance the Proper Distances on ALL THREE PADS:
Listen to Nick...
(2) Damaging the Mating Slots of the TC as it slides into the opening of the TC Pump via Clumsy, Careless Installation Technique... requiring that it pass 2 sections to get "Stabbed-In".
Internal Stator Vane Bearing Assembly Damage or Friction Plate Internals can also make noise if NOT properly Lubricated by a Working Fluid Pump.
Remember... The 4L60E Torque Converter is NOT a Solid State Mechanism... it HAS Internal Moving Parts that CAN become Damaged:
(3) Excessive Wear of the Crankshaft Thrust Bearings such that the TC "Hunts" longitudinally TOO MUCH and thus, the Flex-Plate-TC will move in and out and can destroy the Inner TC Pump Vanes (TABS) as illustrated in the first Video.This Flexing can also occur around the Center Bolt Matrix at the Crank-Shaft ... work hardening the Plate until it Cracks.
(4) Improper Installation and Torque applied upon the Three TC Flex-Plate Bolts. In some cases...there is an OVAL Hole that needs to be set on one particular TC Boss Pad out of all Three.
Also... Having JUST ONE LOOSE BOLT is enough to set the stage for it to self destruct.
(5) Installing the
WRONG Torque Converter or one with Internal Damage. Always Pre-Fill the TC prior to Installation. Gradually TOP OFF the Transmission with the Engine Idling in Park. DO NOT OVERFILL THE 4L60E.
(6) BAD MOTOR MOUNTS...can Contribute to TC Failure since the Massive Rotational Parts are always fighting against Torque and Angular Momentum from the Input Power of the Engine... getting "jounced around" and if the Engine moves too much, it can only add to the problem.